Corrosion-related failures in heat exchangers

Murad Ali, Anwar Ul-Hamid*, Tayyab Khan, Abdulhakim Bake, Haider Butt, Olufemi Eyitope Bamidele, Aamer Saeed

*Corresponding author for this work

Research output: Contribution to journalReview articlepeer-review

3 Scopus citations


Corrosion is the primary cause of failure of heat exchangers in industry, especially in the oil and petrochemical sector. The modes of failure related to corrosion include erosion corrosion, pitting corrosion, crevice corrosion, grain boundary corrosion, dealloying, galvanic corrosion, stress corrosion cracking, waterside corrosion, uniform corrosion, and microbially induced corrosion. Primary causes of corrosion-related failures were found to be fabrication and welding defects, presence of residual stresses, inappropriate materials selection and design, improper water chemistry/flow and poor choice of filters, presence of corrosive species such Cl-, Sx-, O2, NH4+ in water, nonadherence to recommended operating conditions, and noncompliance with standard practices during the shutdown. This article is a review covering only corrosion-related failures in heat exchangers.

Original languageEnglish
Pages (from-to)519-546
Number of pages28
JournalCorrosion Reviews
Issue number6
StatePublished - 1 Dec 2021

Bibliographical note

Publisher Copyright:
© 2021 Walter de Gruyter GmbH, Berlin/Boston.


  • crevice corrosion
  • failure analysis
  • heat exchanger
  • pitting corrosion
  • stress corrosion cracking

ASJC Scopus subject areas

  • General Chemistry
  • General Chemical Engineering
  • General Materials Science


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