Case Study Summary
This case study examines how Apex mitigated iron and copper transport during boiler startup at a power generation facility by implementing a film-forming corrosion inhibitor program. By stabilizing metallurgy during cycling and startup conditions, the facility reduced metal transport, improved system cleanliness, and enhanced long-term asset protection.
Power generation facilities that cycle frequently or experience extended outages are particularly vulnerable to corrosion during startup. Oxygen ingress, low pH conditions, and inadequate protective films can result in significant iron and copper transport, leading to deposition, efficiency loss, and long-term equipment damage.
A natural gas–fired power plant experienced elevated iron and copper levels during startup events following outages and maintenance periods. These metal excursions raised concerns about deposition in boilers and condensate systems, prompting the plant to seek a more effective corrosion control strategy focused specifically on startup and layup conditions.
Results at a Glance
Significant Reduction in Iron & Copper transport during Startup Events
Improved Condensate and Boiler water cleanliness
Enhanced Asset Protection during cycling and outage recovery
Facility Background
- Industry: Power Generation
- Application: Boiler and condensate corrosion control during startup
- Primary Issue: Elevated iron and copper transport caused by startup corrosion
- Apex Solution: FilmProâ„¢ Nexus BC-1452 Film-Forming Corrosion Inhibitor
The facility operates a natural gas–fired power plant subject to frequent cycling and planned outages. During startup, rapid temperature changes and oxygen exposure created aggressive corrosion conditions, particularly in condensate and feedwater systems. Elevated iron and copper transport posed risks to heat transfer surfaces, turbine efficiency, and long-term reliability.
The Challenge
The power plant faced several startup-related challenges:
- Elevated iron and copper levels during startup events
- Oxygen ingress during outages and layup periods
- Inadequate protective films on metal surfaces
- Increased risk of deposition on heat transfer surfaces
- Potential long-term damage to boilers, turbines, and condensate systems
Traditional corrosion control methods provided limited protection during dynamic startup conditions.
The Apex Solution
Apex implemented a film-forming corrosion inhibitor (FFCI) program designed to protect metal surfaces during both operation and startup.
Key elements of the solution included:
- Application of FilmPro™ film-forming chemistry to create a hydrophobic protective layer on metal surfaces
- Integration of the program into existing boiler and condensate treatment protocols
- Targeted dosing during startup and post-outage recovery
- Monitoring of iron and copper levels to evaluate performance
- Ongoing field support to optimize application timing and dosage
The film-forming approach provided immediate surface protection, reducing metal loss during transient conditions.
Results & Operational Impact
Following implementation of the FilmProâ„¢ program, the facility observed measurable improvements:
- Reduced iron and copper concentrations during startup, indicating lower corrosion rates
- Improved clarity and cleanliness of condensate samples
- Decreased risk of deposition in boilers and heat exchangers
- Enhanced protection of critical assets during cycling operations
By addressing corrosion at the source, the facility improved reliability while reducing long-term maintenance risk.
Applicable To
This solution is relevant for:
- Cycling or peaking power plants
- Facilities with frequent startups and shutdowns
- Plants experiencing iron or copper transport during outages
- Operations seeking enhanced asset protection without equipment changes
Conclusion
This case study demonstrates how film-forming corrosion inhibitors can effectively mitigate metal transport during boiler startup. By applying a targeted corrosion protection strategy, Apex helped this power generation facility reduce iron and copper excursions, protect critical assets, and improve long-term system reliability.
For power plants facing startup-related corrosion challenges, Apex delivers advanced solutions that address dynamic operating conditions with proven results.
Case Study Summary
Why is corrosion more aggressive during startup conditions?
Startup introduces oxygen, temperature swings, and unstable chemistry, all of which accelerate corrosion if protective films are not present.
How do film-forming corrosion inhibitors work?
Film-forming inhibitors create a hydrophobic barrier on metal surfaces that limits oxygen and water contact, reducing corrosion even during transient conditions.
Can FilmProâ„¢ be integrated into existing boiler treatment programs?
Yes. FilmProâ„¢ is designed to complement existing boiler and condensate treatment strategies without requiring system modifications.
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