Corrosion Resistance of Carbon Steel and Inconel-Cladded Carbon Steel in Petrochemical Pressure Vessels

This investigation primarily focuses on addressing the challenges posed by the traditional use of carbon steel, which, despite its strength and cost-effectiveness, is prone to rapid corrosion in harsh chemical environments within the petrochemical industry. This issue constitutes a chronic operational vulnerability, exacerbated by extreme environmental stressors. The combined effect of corrosive atmospheres and rigorous EHSS (Environment, Health, Safety, and Security) mandates creates a significant fiscal burden, primarily driven by escalated lifecycle maintenance and the necessity for specialized regulatory compliance. Integrating Inconel, known for its exceptional corrosion resistance and durability, particularly at high temperatures, will significantly enhance the lifespan, safety, and operational efficiency of these vessels. This investigation aims to study the corrosion resistance of carbon steel specimens and carbon steel specimens clad with Inconel at thicknesses of 2 mm and 4 mm in different environments: acidic pH = 2 (HCl), neutral pH = 7 (distilled water), and alkaline pH = 12 (NaClO). All specimens were tested at the same immersion intervals of 5 and 10 days. Corrosion resistance was measured for the immersion corrosion tests. Weight loss in the specimens was measured before and after immersion to calculate the corrosion rate, and surface analysis was conducted using a scanning electron microscope (SEM). It was observed that at pH = 12 (NaClO), carbon steel corrosion reached a rate of 6.96 mm/year, while Inconel showed very low corrosion, 0.05 mm/year, indicating a resistance 139 times greater than that of carbon steel. At pH = 2 (HCl), carbon steel corrosion reached a rate of 1.29 mm/year, while Inconel showed a very low corrosion rate of 0.015 mm/year, indicating a resistance 86 times greater than that of carbon steel. In a neutral environment, all materials exhibited approximately the same corrosion rate between 0.0017 and 0.12 mm/year. This indicates that Inconel is highly resistant to corrosion in both acidic and alkaline environments, making it suitable for petrochemical plants.