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23-06: Maximum Soluble Inhibitor as a Point of Diminishing Returns

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Volumes of information are available in the literature for the computer modeling of scale formation and its control, but few studies have been published on the modeling of corrosion and its inhibition in aerated cooling water systems. Frequent questions from users of water chemistry modeling software include
What corrosion rates can be expected for carbon steel and common alloys as functions of water chemistry, temperature, pH, and inhibitor dosage?
What inhibitor dosage will be required to achieve a target corrosion rate?
Can you profile corrosion rate as a function of water chemistry parameters and inhibitor dosage?
What are the relative costs projected to achieve different degrees of corrosion control?
This paper constitutes a status report on the development of the data required to develop models for relative corrosion rates as a function of water chemistry and inhibitor dosage, and similar models to correlate water chemistry to corrosion rates and inhibitor dosage. Solubility limited inhibitors are defined as those that can precipitate and form deposits when fed at a concentration higher than their maximum solubility for a given water. This paper emphasizes orthophosphate, arguably the most common mild steel corrosion inhibitor applied in open recirculating cooling systems. Other solubility limited inhibitors include zinc and polyphosphates such as pyrophosphate. These inhibitors, and combinations, will be covered in future papers. It was observed that relative corrosion rates decrease as inhibitor dosage increases. The beneficial impact of the inhibitor plateaus and approaches a minimum beyond the maximum inhibitor solubility for a given water.  At higher dosages, where precipitation occurs, corrosion rates have been observed to increase with increased dosage. The models discussed are directed towards aerated cooling water systems.

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