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Common Causes of Corrosion in RTO Units
Release time:
2026-07-13
RTO Corrosion of equipment is not attributable to inherent quality issues of the equipment itself; rather, it arises from the formation of corrosive species during high‑temperature combustion of the complex constituents in pharmaceutical and chemical exhaust gases. This paper will systematically elucidate the underlying corrosion mechanisms.
First is acid formation through high-temperature oxidation; this is… RTO The common corrosion pathways of equipment involve chlorine- and sulfur-containing organic compounds in the exhaust gas. RTO In the high-temperature, oxygen-rich environment of the combustion chamber, oxidation produces acidic gases such as hydrogen chloride and sulfur dioxide. When the temperature drops below the acid dew point, these acidic gases condense into liquid acids that corrode metals; control… RTO Maintaining an outlet temperature consistently above the acid dew point is key to preventing this type of corrosion.
Second, there is high-temperature chloridic embrittlement and stress corrosion, which are more insidious and far more destructive. Free chlorine or chloride ions in the exhaust gases of pharmaceutical intermediates, in… RTO In the high-temperature heat‑storage zone, metal grain boundaries become infiltrated, leading to the formation of low‑melting-point metal chlorides. This type of corrosion is unevenly distributed and tends to initiate at welds and stress‑concentration areas. Initially, the surface appears undisturbed, but the interior has already been compromised; by the time it is detected, significant strength loss has often already occurred. 30% to 50% After treating chlorine‑containing epoxy resin‑based exhaust gases, there is a high risk of stress corrosion cracking in critical components such as rotary valves and heat‑storage support structures, necessitating stringent preventive measures.
Third is low-temperature dew-point corrosion, which becomes more pronounced when equipment is shut down or operates intermittently. RTO During normal operation, the overall temperature is high, resulting in a low risk of corrosion. After shutdown, temperatures in the lower furnace and other components gradually decline. If residual acidic gases remain at elevated concentrations, once the wall temperature drops near the dew point, these gases can condense into highly concentrated acid solutions that continue to corrode the metal—particularly in pharmaceutical companies with intermittent production schedules. RTO Daily start-ups and shutdowns—each shutdown and subsequent cooling period represents a high-risk phase for corrosion—have been observed in pharmaceutical companies. RTO After one year of operation, the wall thickness of the lower furnace body decreased; this was confirmed to be caused by dew-point corrosion during nighttime shutdowns.
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