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Corrosion protection: Taking effective measures against corrosive gases

Corrosion poses a constant threat to industry, leading to significant economic losses, safety risks, and declines in efficiency due to the decomposition of materials caused by chemical reactions with the environment. Corrosive agents such as sulphur dioxide (SO₂), hydrogen sulphide (H₂S), nitrogen dioxide (NO₂), chlorine (Cl₂), and other acid gases are particularly problematic. A highly effective method to combat and control industrial corrosion is molecular air filtration, especially when using impregnated activated carbon as a filter medium. This technology enables companies to reliably filter corrosive gases in order to prevent corrosion and maintain safe and successful operations.

Preventing corrosion: The crucial role of molecular air filtration

The issue of corrosion and its prevention rarely receives the attention it deserves. While highly corrosive industries, such as oil and gas, have long been vigilant when it comes to corrosion protection, many other sectors still underestimate the challenge. Chemical corrosion, especially in pipelines, metals, and electronic equipment, can cause machine failures, personal injuries, and substantial economic losses, damaging a company's reputation. Beyond traditional active and passive corrosion protection measures such as corrosion inhibitors or cathodic protection, the adsorption of harmful corrosive gases by high-performance air filters is vital.

Corrosive substances release gases like nitrogen dioxide (NO₂) and hydrogen fluoride (HF), which threaten electronic and electrical control systems. Sulphur-containing gases, including sulphur dioxide (SO₂), sulphur trioxide (SO₃), and hydrogen sulphide (H₂S), can cause severe corrosive damage. Molecular air filtration, however, helps effectively adsorb these and other corrosive gases from the air before they contact materials and cause damage. At MANN+HUMMEL, we use highly effective, specially impregnated activated carbon at the heart of this technology.

In comparison:

A printed circuit board (PCB) in its original condition next to a corroded PCB. The corroded PCB shows clear signs of damage caused by moisture and chemical reactions. The corrosion causes a short-circuit.

Impregnated activated carbon against corrosion damage

Activated carbon is ideal for corrosion protection due to its high adsorption capacity and unrivalled ability to successfully bind a wide range of organic and inorganic gases. Its effectiveness can be further enhanced by impregnating it against specific corrosive chemicals.

There are different approaches to optimise the effectiveness of corrosion protection systems using impregnated activated carbon:

Customised impregnations

The adsorption capacity and selectivity of activated carbon can be further enhanced by selecting and developing impregnations specially tailored to specific corrosive gases. Factors such as the chemical composition, pore size, and surface structure of the carrier material are crucial.

Multi-stage filtration

Using multi-stage filtration systems with different impregnated activated carbons can significantly improve corrosion control. Sequential filter stages designed for various gases ensure the reliable removal of a wide range of corrosive gases.

Optimised flow routing

The design of flow routing within the filtration system significantly impacts the effectiveness of gas adsorption. Simulations and practical tests can help optimise flow profiles in order to ensure even air distribution and maximum utilisation of the adsorption material.

Intelligent monitoring and control

Integrating sensor technologies and intelligent control systems offers exciting new possibilities for optimising corrosion protection. Continuous monitoring of parameters such as gas concentrations, humidity, and temperature enables real-time filter performance tracking and any required adjustments as needed.

Corrosion coupons provide a cost-effective means of monitoring that allows you to effectively measure the corrosivity within your system.

Preventive maintenance and services

Regular maintenance and replacement of filter media is crucial for the long-term effectiveness of corrosion control. Preventive maintenance extends the service life of impregnated activated carbon and ensures a consistently high-level of protection.

By combining these approaches, the effectiveness of corrosion protection with impregnated activated carbon can be continually improved. However, the selection of the right adsorption material and level of impregnation depends on the specific corrosive gases to be addressed. That’s why we help our customers with identifying the optimal solution for their specific applications.

Corrosion protection with MANN+HUMMEL: Fully customised solutions for every industry

For over 80 years, we’ve been safeguarding industries with our customised molecular air filters that protect plants, infrastructures, people, and machines.

For inquiries about specific applications and potential solutions, the MANN+HUMMEL team is here to help you. Contact us today to discover how we can help support your corrosion management strategy.

Contact us

At MANN+HUMMEL, we’re here to support your air filtration needs! Whether you have questions about our products or need tailored solutions, our expert team is ready to assist you. Reach out to us via email or telephone to discuss your requirements, and let’s work together to enhance your air quality. Contact us today and experience exceptional service tailored to your business!