A Detailed Review of Numerical Modeling of Flow Accelerated Corrosion: Challenges and Opportunities for the Future

Flow-accelerated corrosion (FAC) is a complex phenomenon that poses a significant threat to the integrity of piping and fittings in power plants, affecting infrastructure protection and power production reliability. The presence of corrosive substances in the fluid and elevated flow velocity and temperature leads to increased material loss in piping and equipment. Understanding the intricate relationship among the contributing factors such as flow dynamics, environmental factors, and corrosion reactions is essential for developing effective prediction and mitigation strategies. This review discusses the recent advancements in the numerical modeling of FAC using computational fluid dynamics (CFD). The numerical models presented show abilities to predict FAC profiles across multiple power plant components, and a review was conducted on the evaluation of these predictions with experimental measurements. Notably, increased turbulence in the flow significantly contributed to prediction errors, emphasizing the need for advanced turbulence models in numerical simulations of FAC. Addressing these challenges is crucial for maintaining sustainable infrastructure and reducing industrial risks through enhanced predictive maintenance strategies.