4.

0 Caustic Corrosion
Introduction

Caustic corrosion/gouging occur when alkalinity of boiler water increases. Caustic corrosion is
also called caustic attack. Caustic corrosion develops from deposition of feed water corrosion
products in which NaOH can concentrate to high PH levels.

Mechanism

At high PH level, the tube steels protective magnetic oxide coating is solubilized and rapid
corrosion occurs as per the reaction given below:

4NaOH + Fe3O4 2NaFeO2 +2H2O

With the destruction of protective magnetic oxide layer, concentrated NaOH reacts with the tube
material and forms atomic hydrogen as per the reaction

Fe + 2NaOH Na2FeO2 +2H

Prevention

Inspections of boilers with caustic attack often show excessive accumulations of magnetic oxide
in low flow areas of drums and headers. This is caused by the flaking off, during operation, of
deposits under which the complex caustic-ferritic material has formed. When contacted and
diluted by boiler water, this unstable complex immediately reverts to free caustic and magnetic
oxide. The following action in particular can be taken.

Prevent in-leakage of alkaline-producing salts into condensers monitored. Suspicion

should be aroused if a short-term failure occurs immediately after another failure.
Prevent inadvertent release of caustic regeneration chemicals from makeupwater
demineralizers.