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Corrosion in bioprocessing applications

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Abstract

Corrosion in bioprocessing applications is described for a 25-year-old bioprocessing pilot plant facility. Various available stainless steel alloys differ greatly in properties owing to the impact of specific alloying elements and their concentrations. The alloy property evaluated was corrosion resistance as a function of composition under typical bioprocessing conditions such as sterilization, fermentation, and cleaning. Several non-uniform forms of corrosion relevant to bioprocessing applications (e.g., pitting, crevice corrosion, intergranular attack) were investigated for their typical causes and effects, as well as alloy susceptibility. Next, the corrosion resistance of various alloys to specific bioprocessing-relevant sources of corrosion (e.g., medium components, acids/bases used for pH adjustment, organic acid by-products) was evaluated, along with the impact of temperature on corrosion progression. Best practices to minimize corrosion included considerations for fabrication (e.g., welding, heat treatments) and operational (e.g., sterilization, media component selection, cleaning) approaches. Assessments and repair strategies for observed corrosion events were developed and implemented, resulting in improved vessel and overall facility longevity.

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Abbreviations

CCI:

Crevice corrosion index

CCCT:

Critical crevice corrosion temperature

CIP:

Clean-in-place

DO:

Dissolved oxygen

DP:

Differential pressure

DPI:

Dye penetrant inspection

HAZ:

Heat affected zone

HEX:

Heat exchanger

ID:

Inner diameter

IGA:

Intergranular attack

IGC:

Intergranular corrosion

IGSCC:

Intergranular stress corrosion cracking

KLA:

Knife-like attack

MIC:

Microbiologically-influenced corrosion

MIG:

Metal inert gas [also gas metal arc welding (GTAW)]

PREN:

Pitting resistance equivalent number

RMS:

Root mean square

SCC:

Stress corrosion cracking

SMA(W):

Shielded metal arc welded or “stick” welded, uses covered wire

SS:

Stainless steel

TGSCC:

Transgranular stress corrosion cracking

TIG:

Tungsten inert gas [also gas tungsten arc welding (GTAW)], uses bare wire

a Cl :

activity of chloride ion

A, B :

alloy specific coefficients of the pitting potential equation (Eq. 9)

D :

maximum depth of attack

Cr eq:

chromium Hammar and Svensson equivalents, wt.%

E p :

pitting potential, potential above which pits may nucleate and grow but below which it is unlikely for pitting to occur

Ni eq:

nickel Hammar and Svensson equivalents, wt.%

r :

corrosion rate (Arrhenius rate equation)

S :

number of sides attacked

T :

absolute temperature, K

T c :

crevice corrosion temperature below which no crevice corrosion occurs, °C

T p :

critical pitting temperature below which no pitting occurs, °C

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Acknowledgments

The author would like to acknowledge helpful discussions with the following consultants: Arthur Tuthill (Tuthill Associates, Blacksburg VA), Robert Odle/Rick Corbett (Corrosion Testing Laboratories, Newark, DE); Dick Avery (Avery Consulting, Londonderry, NH), and Hira Ahluwalia (DoctorMetals, Pennington, NJ). Also, the patience and dedication of personnel associated with the Merck Rahway Fermentation Pilot Plant, Pilot Facilities Engineering, and Maintenance and Installation groups, particularly its welders, in investigating, performing, and testing these repairs.

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    Beth Junker

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Junker, B. Corrosion in bioprocessing applications. Bioprocess Biosyst Eng 32, 1–29 (2009). https://doi.org/10.1007/s00449-008-0223-7

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