Careers How to Prevent Microbially Influenced Corrosion (MIC) with On-Site Alloy Upgrade
Microbiologically Influenced Corrosion (MIC) is a significant issue in various industries, including petrochemical, power, waste, and oil/gas environments. MIC is responsible for about 20% of all corrosion costs globally, amounting to hundreds of billions of dollars. This type of corrosion is caused by microbial activity, leading to the formation of corrosive metabolic by-products such as hydrogen sulfide (H₂S) and sulfuric acid (H₂SO₄). One of the most effective ways to prevent MIC in tanks and vessels is through on-site alloy upgrades using High Velocity Thermal Spray (HVTS®) claddings. Integrated Global Services (IGS) offers a robust solution to combat MIC with advanced alloy HVTS systems.
Understanding Microbiologically Influenced Corrosion (MIC)
MIC occurs when microbes attach to metal surfaces and form biofilms. These biofilms accelerate corrosion through various mechanisms, including the formation of concentration and differential aeration cells, direct oxidation/reduction of metallic atoms/ions, and the production of corrosive metabolic by-products. Both aerobic and anaerobic organisms can contribute to MIC, with biogenic sulfide corrosion being one of the most common and destructive mechanisms.
The Role of High Velocity Thermal Spray (HVTS) Claddings
HVTS is a corrosion mitigation technique where a corrosion-resistant metal alloy is atomized and sprayed at high velocity onto a substrate, such as carbon steel. This process forms a corrosion-resistant and mechanically superior barrier over the substrate. IGS’s HVTS systems have been validated as effective barriers against MIC, preventing corrosion of the underlying carbon steel. The process is limited to line-of-sight conditions allowing to work within vessels having internal diameters above 400 mm (16”.)
Benefits of On-Site Alloy Upgrades with IGS HVTS
1. Effective Barrier Against MIC: IGS HVTS claddings have been proven to prevent corrosion in different environments. Applied on-site, high-alloy cladding protects vessels and tanks
2. Durability and Longevity: Even after prolonged exposure to corrosive environments, the cladding remains in nearly as-applied condition.
3. Cost-Effective Solution: Preventing MIC can reduce maintenance costs and extend the lifespan of critical equipment, resulting in significant cost savings over time.
4. Versatility: Alloy upgrade systems can be applied to various substrates and are suitable for various industries, including petrochemical, power generation, and energy.
The IGS HVTS Process
The HVTS process involves several steps to ensure optimal performance and durability:
Surface Preparation: The substrate is thoroughly cleaned and prepared to ensure proper adhesion of the alloy cladding. This includes degreasing, polishing, and sterilizing the surface.
HVTS Application: The corrosion-resistant metal alloy is applied with high-velocity conditions to the prepared substrate. The process parameters are carefully controlled to achieve the desired coating thickness and properties.
Post-Application Analysis: The coated samples are analyzed using various techniques, including visual inspection, laser profilometry, and SEM imaging. This ensures that the HVTS cladding has been applied correctly and provides the desired level of protection against MIC.
Case Study: Validation of IGS HVTS Claddings
IGS has 40-years’ experience in corrosion mitigation and practices scientific approaches to problem solving. To validate the effectiveness of HVTS claddings against MIC, IGS conducted a comprehensive corrosion study.
The study involved culturing Desulfovibrio desulfurisers onto both control and HVTS-clad test coupons. The samples were incubated anaerobically at 37°C for 120 days, with regular media refreshment.
The study’s results were impressive. The control samples showed significant pitting, crevice formation, and sulfidation, while the HVTS-clad samples showed no signs of corrosion or degradation. SEM imaging and EDS analysis confirmed the absence of iron-based corrosion products on the HVTS-clad samples, indicating that the cladding effectively prevented MIC.
Conclusion
On-Site Alloy Upgrades Deliver Microbiologically Influenced Corrosion Prevention
Microbiologically Influenced Corrosion is a major challenge for many industries, leading to significant maintenance costs and equipment failures. On-site alloy upgrades using IGS’s HVTS high alloy systems provide an effective and durable solution to combat MIC. By forming a corrosion-resistant barrier over the substrate, HVTS claddings prevent the formation of corrosive biofilms and extend the lifespan of critical equipment.
Learn more about HVTS on-site high alloy systems
For more information on how IGS can help prevent MIC with on-site alloy upgrades, contact our experts.
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