SOFTWARE | OLI STUDIO | CORROSION ANALYZER
Determine the causes of corrosion before it occurs and help evaluate and implement preventive actions, such as choosing the best operating conditions or selection of the right corrosive resistant materials.
First-principles corrosion simulation software
SOFTWARE KEY FEATURES
Corrosion analysis with comprehensive thermophysical and electrochemical modules
The thermophysical module calculates the aqueous solution speciation and obtains concentrations, activities, and transport properties of the reacting species. The electrochemical module simulates partial oxidation and reduction processes on the metal surface. Corrosion Analyzer reproduces the active-passive transition and the effects of solution species on passivity. Effects of temperature, pressure, pH, concentration and velocity on corrosion are included.
The thermophysical module accurately predicts component speciation in aqueous solutions. It employs our rigorously-tested AQ database of over 6,000 chemical species, equilibrium equations, and interaction parameters. This engine calculates concentrations and activities of ions and neutral components by way of the Bromley-Zematis activity equation. It also calculates species transport properties, including viscosity, diffusivity, and electrical conductivity. These properties enable calculation of mass-transfer effects such as the limiting current density.
The crux of the electrochemical module lies in the reduction/oxidation surface half-reaction simulations for elements, alloy components, and aqueous species. Its fraction surface coverage model generates the active-to-passive transition, whereby under the active state, we expect the metallurgy to corrode, and under the passive state, a protective film prevents corrosion. Users gain insight into each species’ limiting current density, which reflects the effects of mass transfer on electrochemical potential.
In addition to the general corrosion that is predicted by the electrochemical module, users can anticipate localized corrosion in the form of pitting or crevice corrosion. This is calculated based on the system’s repassivation potential; at conditions where the repassivation potential is less than the corrosion potential, pitting or crevice corrosion is predicted to occur. Pit formation may also lead to the initiation of stress-corrosion cracking.
The thermophysical module accurately predicts component speciation in aqueous solutions. It employs our rigorously-tested AQ database of over 6,000 chemical species, equilibrium equations, and interaction parameters. This engine calculates concentrations and activities of ions and neutral components by way of the Bromley-Zematis activity equation. It also calculates species transport properties, including viscosity, diffusivity, and electrical conductivity. These properties enable calculation of mass-transfer effects such as the limiting current density.
The crux of the electrochemical module lies in the reduction/oxidation surface half-reaction simulations for elements, alloy components, and aqueous species. Its fraction surface coverage model generates the active-to-passive transition, whereby under the active state, we expect the metallurgy to corrode, and under the passive state, a protective film prevents corrosion. Users gain insight into each species’ limiting current density, which reflects the effects of mass transfer on electrochemical potential.
In addition to the general corrosion that is predicted by the electrochemical module, users can anticipate localized corrosion in the form of pitting or crevice corrosion. This is calculated based on the system’s repassivation potential; at conditions where the repassivation potential is less than the corrosion potential, pitting or crevice corrosion is predicted to occur. Pit formation may also lead to the initiation of stress-corrosion cracking.
Applications
Evaluate the potential for localized corrosion in an isostripper, depropanizer, of HF stripper unit in the fractionation section of your HF Aklylation facility.
Predict corrosion levels based on ionic dew point due to shock condensation, and study how changing conditions can improve unit safety.
Determine risk of general corrosion of the sour water circuit in your hydroprocessing unit to increase its lifetime.
Predict corrosion of geothermal wells based on stream impurities and CO2 levels; couple Corrosion Analyzer with ScaleChem to capture degradation alongside deposits on your system.
Study how bioreactor media, additional inorganic or organic dosing species, and different heating/cooling steps can corrode your process equipment.
Use Pourbaix diagrams to understand the stability of phases in a stream at your battery plant or battery recycling process and identify passive versus corrosion-susceptible regions.
Evaluate if your extracting agent will cause your equipment to become susceptible to corrosion.
Determine if your process streams are stable in the face of your rare earth extraction or mining metallurgy.
Find out if your leaching solution poses a corrosion risk before it enters your crystallizer or filtration unit.
Corrosion rate predictions for cooling towers are critical to ensure that efficient and continuous operations can proceed in other areas of a facility.
Corrosion analyzer can provide insight into corrosive levels of soda ash or lime as you plan your water softening treatment.
Understand how corrosive your recycled process stream is, and how its impact can be mitigated by selecting different metallurgy.
Capabilities
Corrosion cacluations
Pourbaix diagrams are an essential tool for analyzing the behavior of elements in different environments. These diagrams, plotting potential (E) against pH values, provide valuable insights into stable and metastable corrosion products, redox couples, and species activity.
OLI Studio Corrosion Analyzer enable users to evaluate the effects of temperature, pressure, and composition on redox thermodynamics, facilitating the analysis of materials like carbon steels, stainless steels, Ni-base alloys, and Cu-Ni alloys. By leveraging Pourbaix diagrams, engineers and researchers can make informed decisions to enhance durability and prevent corrosion in diverse industrial applications.
Potential (E) vs. species diagrams provide valuable insights into the redox and speciation behavior of target elements or alloys. Depicting the relationship between the potential (E) and the concentration of a species, which impacts the chemical behavior of the element. By utilizing species concentration as the independent variable, users can understand the stability of different redox states and the formation of chemical species. Illustrating how changes in species concentration influence the redox behavior of the element.
Critical concentration ranges can be identified, revealing stable and metastable redox states. The diagrams support the analysis of the speciation behavior of elements in the presence of varying species concentrations, providing insights into the formation of chemical species and complexes.
Determining the rate of general corrosion and corrosion potential in aqueous solutions is vital for a diverse range of materials. This involves calculating the corrosion rate by measuring mass loss or material degradation over time. Additionally, evaluating the corrosion potential provides insights into a material’s susceptibility to corrosion reactions. These assessments cover a broad spectrum of materials used in various industries, aiding in the selection of corrosion-resistant options and ensuring long-lasting performance in aqueous environments.
By accurately calculating the rate of general corrosion and determining the corrosion potential, users can identify materials’ susceptibility to corrosion and devise appropriate mitigation strategies. This knowledge helps in selecting corrosion-resistant materials, optimizing designs and ensuring the longevity and reliability of structures and components in contact with aqueous solutions.
Understanding the mixed potential and corrosion current density is crucial in evaluating corrosion. Polarization plots reveal the equilibrium between anodic and cathodic reactions, representing the overall corrosion tendency.
By examining critical points on the plots, users can pinpoint where these reactions occur and determine the associated corrosion current density. This knowledge assists in identifying potential areas of concern and reaching informed decisions to mitigate corrosion. Polarization plots serve as powerful tools for comprehending corrosion mechanisms and informing strategies for corrosion prevention and control.
Heat treatment of stainless steels and nickle-base alloys can lead to significant effects on the composition and properties of these materials. One crucial aspect is the depletion of elements such as chromium (Cr), molybdenum (Mo) and tungsten (W) in grain boundaries. Predicting this depletion enables the evaluation of intergranular corrosion susceptibility and the impact of heat treatment on localized corrosion.
By predicting the depletion of Cr, Mo, and W in grain boundaries because of heat treatment, users can assess intergranular corrosion susceptibility and the impact of heat treatment on localized corrosion. This knowledge is essential for optimizing heat treatment processes, selecting appropriate alloys, and implementing corrosion prevention strategies to enhance the durability and performance of stainless steels and Ni-base alloys in various applications.
OLI Systems Windows Software
Advanced predictive analysis for multi-component systems
We provide comprehensive analysis and predictions of electrolyte and nonelectrolyte stream behavior in multi-component systems, utilizing first principles-based calculations for multi-point equilibrium. Our solutions cover a wide range of operating conditions, aiming to enhance operational efficiency, sustainability, and productivity.
In-depth electrochemistry studies, equilibrium for single point, survey, mix, and separate calculations.
In-depth chemistry studies and prediction of scaling problems for oil and gas production.
Steady-state process simulation for multi-phase systems to improve process design, troubleshoot operations and ensure compliance.
Learn more about OLI Flowsheet: ESP
In-depth electrochemistry studies, equilibrium for single point, survey, mix, and separate calculations.
In-depth chemistry studies and prediction of scaling problems for oil and gas production.
Steady-state process simulation for multi-phase systems to improve process design, troubleshoot operations and ensure compliance.
Learn more about OLI Flowsheet: ESP
