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Corrosion due to leakage at the tee in the acid water return line for hydrogen production from methanol

2026-07-30View Original

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I. Core causes of corrosion and leakage: Medium corrosion: Components such as CO₂ and H₂S dissolved in acidic water form acidic aqueous solutions upon condensation, which have a strong corrosive effect on carbon steel materials. Erosion synergy: Vortices form at the tee junctions, and the solid particles and ammonium salt deposits carried by these vortices continuously erode the pipe walls, accelerating the breakdown of the protective layer and increasing the corrosion rate. Structural stress defects: The uneven wall thickness distribution within the tee itself, along with welding-induced stress concentrations, can lead to corrosion-induced thinning or even perforation at the weak points. II. Emergency response measures: Isolate the hazard source – sever the pipelines and equipment connected to the leakage point in order to prevent further leakage of the medium. On-site safety control: Rinse the residual materials in the area where there was a leak with clean water to reduce the concentration of the substances present on site and avoid safety risks. Plugging leaks under pressure: Handiko polymer composite materials are used for on-site repair; no welding is required, making it suitable for environments with flammable and explosive hazards, and it allows for rapid sealing of leak points. III. Long-term prevention and control plan: Material upgrade – Replace the original carbon steel tees with 300-series austenitic stainless steel or Q345R+S304L composite plates to improve resistance to acidic corrosion. Process optimization: Adjust the pipeline layout to reduce vortex areas, optimize the heating method to prevent localized condensation, and control the flow rate of the medium to minimize erosion effects. Corrosion prevention maintenance: Add film-forming corrosion inhibitors at compliant concentrations to create a dense protective layer on the pipe walls, and regularly inspect the wall thickness to identify potential corrosion risks.

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