Sylvie Willis
Diesel fuel is a type of fuel that is commonly used in vehicles and for various industrial purposes. While diesel is a crucial energy source, one of the concerns surrounding its use is the potential for corrosion in storage tanks and automotive components. This issue has gained significant attention, with the EPA conducting extensive surveys and studies to understand the prevalence and impact of corrosion in diesel fuel storage tanks. The presence of water, impurities, and microbial activity in diesel fuel have all been identified as contributing factors to corrosion. Additionally, the type of diesel fuel, such as conventional diesel or biodiesel, and the specific metal it comes into contact with, can influence the extent and nature of corrosion. Understanding the corrosive effects of diesel fuel on metal is essential for maintaining the integrity of storage tanks, fuel systems, and engines, as well as ensuring the safe and efficient utilization of diesel fuel.
| Characteristics | Values |
|---|---|
| Corrosiveness of diesel fuel | Diesel fuel can cause corrosion in metal tanks. |
| Corrosiveness of biodiesel | Biodiesel is more corrosive to metals than conventional diesel. |
| Metals affected by biodiesel | Copper, aluminium, ferrous alloys, and non-ferrous alloys are susceptible to corrosion from biodiesel. |
| Metal components in diesel tanks | Turbine pump shafts, tank gauge probe shafts, flapper and ball valves, bungs, fuel suction tubes, and tank inner walls are all metal components in diesel tanks that can be affected by corrosion. |
| Factors influencing corrosiveness | The presence of water, oxygen, microbes, and impurities in the fuel can increase the corrosiveness of diesel and biodiesel. |
| Preventing corrosion | The EPA recommends controlling water in tanks, filtering fuel, using biocides and anti-corrosion treatments, and regularly inspecting and repairing tanks to prevent and mitigate corrosion. |
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What You'll Learn
- Biodiesel is more corrosive than diesel, especially to copper and aluminium
- Water in tanks can cause corrosion—the EPA recommends keeping tanks dry
- Microbes that feed on biofuels can cause microbial-induced corrosion
- Metal components in fiberglass tanks can corrode
- Corrosion was observed on all types of metal components in diesel tanks
Biodiesel is more corrosive than diesel, especially to copper and aluminium
Biodiesel is a renewable biomass-based diesel fuel made from plant oils, animal fats, and waste greases. It is used as an alternative to petroleum-based diesel to reduce environmental pollution and combat global warming. However, biodiesel has some disadvantages, including oxidation stability, corrosion, degradation, and incompatibility with certain metallic materials.
Several studies have compared the corrosive characteristics of petroleum diesel and biodiesel. These studies have found that biodiesel is more corrosive than diesel fuel, especially to mild steel, copper, and aluminium. The corrosion rate of rapeseed biodiesel, for example, was found to be 0.0182 mm/year after being immersed for 60 days at 43°C, while the corrosion rate of diesel was significantly lower at 0.0015 mm/year under the same conditions.
The higher corrosivity of biodiesel is attributed to its high water content and acidity, as well as the presence of active oxygen atoms and other volatile compounds. These factors contribute to the formation of small pits (micropits) on the metal surface, which can create a "protective layer" and eventually decrease the corrosion rate. However, prolonged exposure of mild steel to high-quality biodiesel can still affect the metallic surface and piston parts.
Stainless steel 316 has shown high compatibility with biodiesel-diesel blends. The corrosion rates for B5–B10, B15–B20, and B25–B30 blends were found to be relatively low, ranging from 0.0354 to 0.2125 nm/year after full observation at 14,400 hours. Additionally, pre-blending biodiesel with diesel fuel can help reduce the corrosivity of mild steel.
Overall, while biodiesel offers environmental benefits, its higher corrosivity compared to diesel, especially for certain metals like copper and aluminium, is a factor to consider when using it as an alternative fuel source.
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Water in tanks can cause corrosion—the EPA recommends keeping tanks dry
Water tanks are essential for storing and supplying water for various purposes, from drinking to irrigation. However, water tanks can develop corrosion over time, affecting water quality and reducing the tank's lifespan. Corrosion is a natural electrochemical process where metal interacts with its environment, leading to the degradation of the tank's metal material due to chemical reactions with water and other substances. This can result in structural damage, leaks, and contamination of the stored water.
The Environmental Protection Agency (EPA), in collaboration with private industry groups, conducted a comprehensive survey and study of storage tank corrosion. They found that corrosion was more prevalent than expected, with 83% of the tanks surveyed exhibiting moderate to severe corrosion on various metal components, including turbine pump shafts, tank gauge probe shafts, valves, fuel suction tubes, and the tank inner walls. The EPA also observed that the appearance of corrosion damage on turbine pump shafts resembled layers of tubercles covering the metal surface.
Water quality plays a crucial role in tank corrosion. Water with high levels of dissolved minerals, such as iron, manganese, and calcium, is more corrosive. Acidic or alkaline water can also accelerate corrosion. Additionally, oxygen in water can lead to the formation of rust (iron oxide) through oxidation, weakening the tank material over time. Certain types of bacteria can thrive in water tanks, producing corrosive by-products and creating an environment prone to corrosion.
To prevent and manage corrosion in water tanks, several strategies can be employed:
- Regular Maintenance: Implement a schedule for inspection, cleaning, sediment removal, and repainting of the tank to address corrosion issues promptly.
- Proper Coatings and Linings: Apply corrosion-resistant coatings and linings to the tank's interior and exterior. These coatings act as a barrier, preventing the flow of electrons between the tank wall and the water, thus inhibiting corrosion.
- Selecting the Right Tank Material: Choose materials that are less prone to corrosion, such as stainless steel or glass-reinforced plastic (GRP), when installing a new water tank.
- Monitoring Water Chemistry: Regularly test and monitor the water chemistry to maintain optimal pH levels and prevent aggressive water conditions that may promote corrosion.
- Cathodic Protection Systems: Install modern, fully automatic systems that control corrosion and increase the life of coating systems. These systems compensate for changing conditions, including water levels, temperature, and coating effectiveness.
By understanding the causes of corrosion and implementing these preventative measures, water tanks can be well-maintained and long-lasting, ensuring a reliable water supply.
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Microbes that feed on biofuels can cause microbial-induced corrosion
Microbial corrosion, also known as microbiologically influenced corrosion (MIC), occurs when microbes alter the electrochemical environment of the surface they are on. This usually involves the formation of a biofilm, which can either speed up or slow down the corrosion of the surface.
Biofuels like ethanol and biodiesel are prone to microbial contamination due to their affinity for microbes. Microbes that feed on these biofuels can cause microbial-induced corrosion (MIC) in diesel fuel storage tanks. While the link between microbes and biofuels in diesel fuel has not been conclusively proven, the EPA has found strong evidence suggesting this possibility.
In diesel fuel storage tanks, corrosion was observed on various metal components, including turbine pump shafts, tank gauge probe shafts, flapper and ball valves, bungs, fuel suction tubes, and the tank inner walls. This corrosion can lead to issues such as production loss and environmental disasters.
MIC is not limited to metals and can affect plastics, concrete, and other materials. For example, in concrete structures, microbes can alter the pH, creating conditions favourable for more microbes to thrive and accelerate corrosion. Similarly, in jet fuel, hydrocarbon-utilizing microorganisms can cause microbial corrosion of plastic and rubber parts of the aircraft fuel system and metal parts through their acidic metabolic products.
To combat microbial-induced corrosion, a comprehensive understanding of corrosion-causing microbes is necessary. This includes identifying the specific microbes, their interactions, and their mechanisms for breaking down materials. Additionally, various corrosion inhibitors can be used, such as formulae based on benzalkonium chloride, which is common in the oilfield industry.
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Metal components in fiberglass tanks can corrode
Diesel fuel storage tanks are susceptible to corrosion, as an extensive EPA study found. The study revealed that 35 out of 42 tanks surveyed (83%) showed signs of moderate to severe corrosion. Metal components, such as turbine pump shafts, tank gauge probe shafts, and valves, were commonly affected. Corrosion was observed on all metal parts, with the highest levels of damage in the vapor space, the tank's highest point.
Fiberglass tanks are often favoured for their corrosion resistance, but they can still experience corrosion due to their metal components. Unlike metal tanks, fiberglass tanks do not rust or corrode over time, making them a more durable option. However, the presence of metal parts in fiberglass tanks can lead to corrosion issues similar to those in metal tanks.
The EPA study found that corrosion affected both metal and fiberglass tanks equally. The metal components in the vapor space of fiberglass tanks exhibited the most advanced corrosion. This finding highlights the importance of considering the materials used in tank construction and the potential for corrosion in certain environments.
While fiberglass reinforced plastic (FRP) is known for its corrosion resistance, it can be susceptible to environmental stress-corrosion cracking (ESCC). ESCC occurs when fiberglass is simultaneously exposed to mechanical stress and a corrosive environment, typically an acidic one. The glass fibres in FRP, which provide structural strength, can be vulnerable to attack by certain chemicals, leading to premature failure of the fiberglass.
To mitigate corrosion in diesel fuel storage tanks, it is crucial to maintain fuel quality and dryness. Contamination by unexpected substances can contribute to corrosion issues. Additionally, the presence of microbes that feed on biofuels, such as ethanol and biodiesel, can exacerbate corrosion problems. Regular maintenance and monitoring of fuel quality can help prevent corrosion and ensure the longevity of both metal and fiberglass tanks.
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Corrosion was observed on all types of metal components in diesel tanks
Diesel fuel stored in tanks is susceptible to corrosion. In a survey of 42 tanks, 35 (or 83%) exhibited signs of moderate to severe corrosion. Corrosion was observed on all types of metal components in the tanks, including turbine pump shafts, tank gauge probe shafts, flapper and ball valves, bungs, fuel suction tubes, and the tank inner walls. The most common place for corrosion was the turbine pump shafts.
The EPA has found that corrosion affects both metal and fibreglass tanks equally. Metal exposed in the vapor space (the highest part of the tank) had the most corrosion damage. The presence of water during the biodiesel production and purification processes, storage, and use in compression ignition (diesel) engines can cause problems such as corrosion of fuel system components.
The EPA's findings also indicated that microbial-induced corrosion may be a contributing factor. While the study did not prove a link, there was strong evidence to support the possibility. Samples from the tanks commonly had the presence of ethanol and biodiesel, which contribute to corrosion problems due to their affinity for microbes. Microbes feed on biofuels like ethanol and biodiesel.
Additionally, fuel degradation due to metal contact can vary depending on the type of metal. Dissolved oxygen in biodiesel can also influence its corrosive nature to different levels. Copper and aluminium are susceptible to corrosion by biodiesel, whereas stainless steel is more resistant.
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Frequently asked questions
Yes, diesel fuel can corrode metal. However, the rate and extent of corrosion depend on various factors, such as the presence of contaminants, the type of metal, and the duration of exposure.
The presence of contaminants, such as water, ethanol, or biodiesel, can accelerate corrosion. Biodiesel, in particular, has been found to be more corrosive to certain metals, such as copper and aluminium, compared to conventional diesel.
Water can mix with diesel fuel and form an acidic solution, leading to increased corrosion. Additionally, water provides a favourable environment for microbial growth, which can further contribute to corrosion.
Yes, certain metals, such as copper and aluminium, are more prone to corrosion in diesel fuel, especially when exposed to biodiesel. Stainless steel, on the other hand, exhibits higher resistance to corrosion.
Corrosion in diesel fuel storage tanks can lead to significant safety risks and costly repairs. It can damage various metal components in the tank, including turbine pump shafts, tank gauge probe shafts, valves, and fuel suction tubes. Regular maintenance, water removal, and the use of anti-corrosion treatments are crucial to mitigate these issues.
