Every day, industrial machinery faces the constant threat of damage from rust and corrosion. This damage can lead to equipment failures, spills, and leaks, posing risks to people and property. Two effective strategies are protective coating and proactive equipment maintenance. However, some key players in the fight against corrosion are lubricants, specifically those with corrosion-reducing additives. These lubricant additives provide protection every time a component moves, significantly reducing the risk of corrosion. Understanding the differences between lubricant additive products can help maintenance personnel select the right product to combat corrosion and rust to extend equipment life.
The National Association of Corrosion Engineers (NACE) estimates that corrosion costs a staggering $2.5 trillion annually. In the US alone, this figure can reach up to $276 billion, equivalent to 3.1% of the country’s gross domestic product (GDP). And these numbers don’t even include indirect costs such as downtime, increased maintenance expenses, and lower productivity. By implementing corrosion prevention strategies, the world could save between $375 and $875 billion annually.
Common Corrosion Concerns
Industrial environments are fertile grounds for rust and corrosion. Manufacturing equipment is often exposed to chemicals that can accelerate oxidation, and condensation from production processes can seep into gearboxes and chains. This silent threat of rust can damage equipment from the inside out.
Temperature
Some industrial plants experience temperature fluctuations, from the heat produced during operation to cooling from lower temperatures during non-production hours. Heat increases the speed of chemical reactions, and temperature fluctuations can introduce more condensation.
Fluids
Liquids used for cleaning equipment can seep inside machinery, especially if seals are improperly maintained. Any acid in the air or from cleaning products can increase metal degradation.
Wear and Tear
Corrosion weakens the structural integrity of industrial equipment, increasing the risk of failure due to normal wear and tear. It can accelerate equipment deterioration, causing unexpected downtime and repairs, and presents potential safety hazards.
Lubricant Additives
Anti-corrosion additives can be blended into lubricants to minimize damage caused by oxidation. Companies like Allegheny Petroleum, with their specialized knowledge in lubricant blending for industrial equipment, are invaluable resources. Additives can be fine-tuned to inhibit corrosive reactions in wet environments or high-temperature operations. Understanding how corrosive inhibitors can reduce chemical reactions can help business owners ensure that the proper lubricant is used in the right environment, with the guidance of experts like those at Allegheny Petroleum.
Critical Anti-Corrosion Additives in Industrial Lubricants
Anti-corrosion additives inhibit corrosion by forming a protective layer or stabilizing chemical reactions. Selecting the appropriate additives can help mitigate rust formation in various environments. Natural and synthetic inhibitors include:
Amines
Amines form a protective film against water and other corrosive elements on metal surfaces. They can also neutralize corrosive acids, reducing the impact of rust-forming chemical reactions. Because of their water-repellant capabilities, amine-based additives are often used in water treatment plants, boilers, and hydraulic systems.
Phosphonic Acids
These acids convert iron oxide into a more stable compound, such as iron phosphate, to reduce rust formation. Phosphoric acid can dissolve existing rust, making it easier to remove while preventing rust from forming. They are often used in high-temperature and high-pressure environments.
Carboxylic Acids
Commonly used in industrial applications, carboxylic acids form a protective film that prevents the chemical reaction that causes corrosion from being initiated. The additives create a protective layer or bond with metallic ions to form a protective barrier. This barrier protects metal components in manufacturing, transportation, and construction equipment.
Sulfonic Acids
When sulfonic acids come in contact with iron oxide, the chemical reaction turns rust into a water-soluble mixture. This compound cleans rust, scale, and lime deposits from industrial equipment and is often used in power plants, condensers, and pipelines.
Nitrites
Nitrites inhibit iron oxidization. They react with oxygen to create a protective oxide layer on metal surfaces to prevent corrosive agents from reaching the metal surface. They are used in closed-loop cooling systems like engines and industrial equipment, and are most effective on ferrous (iron) metals.
Application-Specific Considerations for Industrial Equipment
How lubricant additives protect against corrosion depends on base oil compatibility, the target metals, and the type of additive(s). Combining corrosion inhibitors can produce a more robust anti-corrosive agent. For example, phosphonic acids protect equipment used in high-temperature manufacturing environments.
Food-processing facilities have stringent safety requirements that require frequent cleaning of equipment. Use of lubricants that repel water, such as sulfonic acids, can limit the amount of liquid that reaches internal components. Infrequently used or outdoor equipment can rust from exposure to its environment. Whether the environments are hot, humid, or exposed to chemicals, industrial equipment is left at the mercy of the elements unless a well-designed maintenance program exists.
Industrial Maintenance Programs
Incorporating equipment lubrication into a scheduled maintenance program is a proactive step that reduces the chance of unexpected equipment failure and downtime. Equipment manufacturers provide guidelines for lubrication maintenance, which may be usage- or condition-based. By following these guidelines, maintenance personnel can take control of equipment longevity and performance.
Usage-Based
Usage-based recommendations suggest checking or changing lubricants at established intervals based on operating hours or elapsed time. Manufacturers may recommend adjusting the intervals based on environmental conditions such as temperature, air quality, and humidity, or operating environments such as high-load or continuous use.
Condition-Based
Condition-based programs suggest regular testing to determine the condition of the lubricant. Analyzing viscosity, oxidation, and additive depletion can identify lubricant degradation. Oil analysis can identify changes in lubrication effectiveness before they damage equipment. Environmental and operational conditions can change, altering lubricant effectiveness.
The American Society for Testing and Materials (ASTM) issues standards for testing corrosion, wear, and abrasion on materials and alloys.
Benefiting From Anti-Corrosion Lubricants
Reducing financial losses due to equipment corrosion impacts a company’s bottom line. Fewer equipment failures and less downtime improve operations and increase productivity. Selecting the proper lubricant additives with corrosion inhibitors can extend the equipment’s usable life. Speaking with an industrial lubricant specialist can help companies identify the appropriate lubricant for their needs. Contact Allegheny Petroleum to talk with a specialist and to develop a maintenance plan for your industrial equipment.