Corrosion is one of the most persistent and costly challenges in wastewater treatment plants. With a mix of harsh chemicals, biological byproducts, and constant flow, equipment is under constant threat. If left unmanaged, corrosion can lead to pipe leaks, sample contamination, and system failure.
How Corrosion Develops
Corrosion is an electrochemical reaction that occurs when metals react with water, oxygen, and other substances. Common contributing factors include:
-
High acidity or alkalinity (pH extremes)
-
Presence of chlorides and sulfates
-
Microbiologically influenced corrosion (MIC) from bacteria
-
Oxygen exposure in storage tanks and piping
Vulnerable Points in a Plant
-
Sample lines and ports
-
Storage tanks and clarifiers
-
Piping joints and weld seams
-
Cooling jackets and heat exchangers
Prevention Strategies That Work
-
Material Selection: Use 316L stainless steel, Hastelloy, or corrosion-resistant coatings in high-risk areas.
-
Proper Sample Conditioning: Control temperature, pressure, and flow to reduce mechanical and chemical stress.
-
Cathodic Protection: Use sacrificial anodes or impressed current systems for underground tanks and piping.
-
Regular Inspection & Testing: Employ ultrasonic testing, corrosion coupons, and visual inspections to monitor damage before failure.
Innovation in Monitoring
Smart sampling systems now offer real-time corrosion data, alerting operators before physical damage becomes critical. Integration with SCADA or IIoT platforms adds an extra layer of safety.
Final Word
Preventing corrosion is not just about avoiding repair costs — it’s about ensuring safety, regulatory compliance, and uninterrupted operations. By taking a proactive, technology-driven approach, wastewater plants can minimize risk and extend the lifespan of critical infrastructure.