Solution Characteristics

Chemical industries can be broadly defined as those that make, use, or dispose of chemicals. The pumps used in these industries are different from those used in other industries primarily in the materials from which they are made. Although cast iron, ductile iron, carbon steel, and aluminum- or copper-base alloys will handle a few chemical solutions, most chemical pumps are made of stainless steel, Hastelloy, the nickel-base alloys, or the more exotic metals, such as titanium and zirconium. Pumps are also available in carbon, glass, porcelain, rubber, lead, and whole families of engineering polymers, including the thermoplastics, thermosets, epoxies, and fluorocarbons. Each of these materials has been incorporated into pump design for just one reason—to eliminate or reduce the destructive effect of the chemical liquid on the pump parts.

Because the type of corrosive liquid to be pumped determines which of these materials is most suitable, a careful analysis of the chemical solution to be handled is the first step in selecting the proper materials for pump construction.

Major and Minor Constituents Foremost in importance in a study of the characteristics of any solution are the constituents of the solution. This means not only the major constituents but the minor ones as well, for in many instances the minor constituents will be the more important. They can drastically alter corrosion rates, and therefore a full and detailed analysis is most critical.

Concentration Closely allied to what the constituents are is the concentration of each. Merely stating "concentrated," "dilute," or "trace quantities" is basically meaningless because of the broad scope of interpretation of these terms. For instance, some interpret concentrated as meaning any constituent having a concentration of greater than 50% by weight, whereas others interpret any concentration above 5% in a like manner. Hence it is always desirable to cite the percentage by weight of each and every constituent in a given solution. This eliminates multiple interpretations and permits a more accurate evaluation. It is also recommended that the percentage by weight of any trace quantities be cited, even if this involves only parts per million. For example, high-silicon iron might be completely suitable in a given environment in the absence of fluorides. If, however, the same environment contained even a few parts per million of fluorides, the high-silicon iron would suffer a catastrophic corrosion failure.

Temperature Generalized terms such as hot, cold, or even ambient are ambiguous. The preferred terminology would be the maximum, minimum, and normal operating temperature. In general, the rate of a chemical reaction increases approximately two to three times with each 18°F (10°C) increase in temperature. Because corrosion can be considered a chemical reaction, the importance of temperature or temperature range is obvious.

A weather-exposed pump installation is a good illustration of the ambiguity of the term ambient. There could be as much as a 150°F (83°C) difference between an extremely cold climate and an extremely warm climate. If temperature cannot be cited accurately, the ambient temperature should be qualified by stating the geographic location of the pump. This is particularly important for materials that are subject to thermal shock in addition to increased corrosion rate at higher temperatures.

Acidity and Alkalinity More often than not, little consideration is given to the pH of process solutions. This may be a critical and well-controlled factor during production processing, and it can be equally revealing in evaluating solution characteristics for material selection. One reason the pH may be overlooked is that it generally is obvious whether the corrosive substance is acidic or alkaline. However, this is not always true, particularly with process solutions in which the pH is adjusted so the solutions will always be either alkaline or acidic. When this situation exists, the precise details should be known so a more thorough evaluation can be made. It is also quite important to know when a solution alternates between acidic and alkaline conditions because this can have a pronounced effect on materials selection. Some materials, although entirely suitable for handling a given alkaline or acidic solution, may not be suitable for handling a solution whose pH is changing.

Solids in Suspension Erosion-corrosion, velocity, and solids in suspension are closely allied in chemical industry pump services. Pump design is a very critical factor when the solution to be pumped contains solids. It is not uncommon for a given alloy to range from satisfactory to completely unsatisfactory in a given chemical application when hydraulic design is the only variable. Failure to cite the presence of solids on a solution data sheet is not an uncommon occurrence. The concentration of solids should be referred to as percent by volume or weight. This undoubtedly is the reason for many catastrophic erosion-corrosion failures.

Aerated or Nonaerated The presence of air in a solution can be quite significant. In some instances, it is the difference between success and failure in that it can conceivably render a reducing solution oxidizing and require an altogether different material for pump construction. A good example of this would be a self-priming nickel-molybdenum-alloy pump for handling commercially pure hydrochloric acid. This alloy is excellent for the commercially pure form of this acid, but any condition that can induce even slightly oxidizing tendencies renders this same alloy completely unsuitable. The very fact that the pump is a self-primer means that aeration is a factor to contend with, and extreme caution must be exercised in using an alloy that is not suitable for an oxidizing environment. The presence of air will not only affect the head-flow rate performance, but also the NPSHR. The maximum amount of air a conventional centrifugal pump can handle is approximately five percent by volume.

Transferring or Recirculating This item is important because of the possible buildup of corrosion product or contaminants, which can influence the service life of the pump.

Such a buildup of contaminants can have a beneficial or deleterious effect, and for this reason it should be an integral part of evaluating solution characteristics.

Inhibitors or Accelerators Both inhibitors and accelerators can be intentionally or unintentionally added to the solution. Inhibitors reduce corrosivity, whereas accelerators increase corrosivity. Obviously, no one would add an accelerator to increase the corrosion rate on a piece of equipment, but a minor constituent added as a necessary part of a process may serve as an accelerator; thus the importance of knowing the presence of such constituents.

Purity of Product Where purity of product is of absolute importance, particular note should be made of any element that may cause contamination problems, whether it be discoloration of product or solution breakdown. In some environments, pickup of only a few parts per billion of certain elements can create severe problems. This effect is particularly important in pump applications where velocity effects and the presence of solids can alter the end result, as contrasted with other types of process equipment where the velocity or solids may have little or no effect.

When a material is basically suitable for a given environment, purity of product should not be a problem. However, this cannot be an ironclad rule, particularly with chemical pumps.

Continuous or Intermittent Duty Depending upon the solution, continuous or intermittent contact can have a bearing on service life. Intermittent duty in some environments can be more destructive than continuous duty if the pump remains half full of corrosive during periods of downtime and accelerated corrosion occurs at the air-liquid interface. Perhaps of equal importance is whether the pump is flushed or drained when not in service.

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