Corrosion is a huge problem for America’s industry. The Cost of Corrosion Study by the National Association of Corrosion Engineers (NACE) estimates the annual cost of corrosion in the U.S. is a staggering $276 billion—approximately 3.1 percent of our nation’s Gross Domestic Product (GDP). Although published in 2002, the study remains an influential industry template on costs and control of corrosion in the U.S.
Surprisingly, one major factor contributing to corrosion isn’t toxic gasses or improper work environments, but water. Specifically, the lack of proper water treatment chemicals in the process. Almost every company that incorporates water in any part of their process, from pulp and paper mills to the food and beverage industry, faces the challenges of corrosion.
Corrosion Cost in the Oil and Gas Sector
One sector notably affected by this is oil and gas. Steel alloy, integral to pressure-pumping equipment during hydraulic fracturing operations, possesses qualities like good strength, heat treatability, and atmospheric corrosion resistance. However, their exposure to chemical oxidants used to manage bacteria in the upstream water treatment process and contaminants like hydrogen sulfide makes them vulnerable to accelerated corrosion rates. Without proactive measures, such corrosion can result in extensive equipment damage, safety hazards, and, eventually, substantial equipment replacement costs.
Breaking Down the Annual Cost of Corrosion in Key Industries
The cost of corrosion study outlined the financial impacts on the oil and gas sector. It highlighted an annual cost of corrosion of about $1.4 billion, with breakdowns including $0.6 billion for surface piping and facility costs, $0.5 billion for downhole tubing, and $0.3 billion for capital expenditures tied directly to corrosion.
Beyond the oil and gas industry, corrosion also plagues:
- The Food and Beverage Industry’s Battle with Corrosion
This sector, which accounts for nearly 14 percent of the nation’s total manufacturing output, grapples with corrosion costs associated with stainless steel used in beverage production, food machinery and more.
- Corrosion Challenges in Pulp and Paper Mills
The $165 billion pulp, paper, and allied products industry supplies the U.S. with approximately 300 kg of paper per person each year. More than 300 pulp mills and 550 paper mills support its production. The harsh processing environments of these facilities make corrosion control especially costly and challenging.
- Cooling Water Towers and the Need for Water Treatment
These systems, integral to many industries, frequently encounter threats like corrosion, scaling, and biological contamination, leading to higher operating costs, equipment repair and replacement, and unplanned downtime.
Innovative Solutions in Upstream Water Treatment
Traditional microbial treatment solutions have often overlooked the potential of incorporating specialized water treatment chemicals. These solutions are typically split into two categories. The first harnesses oxidizers, known for their economical and swift bacterial control. Yet, the predominant oxidizer in use, chlorine dioxide, is not only a volatile, flammable gas posing considerable risks to wellsite personnel but also is notorious for intensifying corrosion cost, as highlighted in various cost of corrosion studies. The latter category leans toward conventional biocides and preservatives. While these agents offer a more durable solution, their higher expense, slower action, and lack of real-time efficacy feedback make them less appealing.
However, a shift is observable in the approach to addressing the annual cost of corrosion. One of the three technical preventive strategies emphasizes the need to propel corrosion technology forward, a sentiment echoed in the NACE Cost of Corrosion Study.
Clean Chemistry took this call to heart. Their newly introduced chemical oxidant technology, initially tailored for the food and beverage industry’s unique needs, showcases a 5.8 percent solution of sodium peracetate. This formulation is designed to unleash significant concentrations of Reactive Oxygen Species (ROS), a move aimed at augmenting product performance. Remarkably, this innovative oxidant stands out as a safer and more budget-friendly option for upstream water treatment, eliminating the hazards tied to traditional oxidizers and without the corrosion costs associated with conventional biocides. It promises prompt water stream treatment and even boasts compatibility with conventional biocides for enhanced, prolonged results.
But the benefits don’t end there. The environment, too, stands to gain from this groundbreaking treatment. The technology champions the conservation of fresh water by significantly cutting down its usage. Moreover, it prioritizes the recycling of water employed in numerous processes and ensures the removal of detrimental chemicals. This meticulous treatment guarantees that “used” water can be confidently disposed of or discharged without environmental repercussions. The culmination of these advantages translates to a tangible reduction in the total cost of operations, a boon for any customer in sectors ranging from restaurant equipment maintenance to pulp and paper mills.
PeroxyMAX™: The Future of Water Treatment Chemicals
At the heart of Clean Chemistry’s advanced solution to the annual cost of corrosion is PeroxyMAX™. This patented liquid oxidant, a standout in the realm of water treatment chemicals, proudly holds EPA registration as a biocide for a multitude of applications. Capable of being produced onsite, PeroxyMAX™ can be seamlessly dosed into the water stream, ensuring a consistent treatment process. Its three primary components, not only being non-hazardous but also storable onsite, have earned the FDA’s GRAS (generally recognized as safe) designation. When comparing PeroxyMAX™ with traditional oxidants and biocides, the advantages are clear: it’s safer, more effective, and offers a more economical solution, helping industries mitigate the corrosion cost.
The versatility of this innovative technology is truly remarkable. Whether it’s food processing plants in the food and beverage industry, the bleach plant within pulp and paper mills, oil or gas rig locations, or even a water cooling tower, PeroxyMAX™ promises safe and efficient upstream water treatment.
For industries like food and beverage, where restaurant equipment’s longevity is paramount, PeroxyMAX™ stands tall. Its reduced corrosion profile when compared to conventional oxidizer chemistries ensures that equipment lasts longer and undergoes fewer repairs or replacements. Furthermore, in the context of pulp and paper mills, PeroxyMAX™ emerges as a less corrosive alternative to traditional water treatment chemicals. Its application significantly minimizes the degradation on machine clothing, emphasizing its role in reducing the overall cost of corrosion.
Combat Corrosion with Clean Chemistry
To combat corrosion and achieve your ESG goals, consider PeroxyMAX for your industry, whether it’s a food processing plant, paper mill, oil rig, water cooling tower or any domain necessitating robust, efficient water treatment. Contact Clean Chemistry today to discover more.