Protect critical electronics in key areas of Fertilizer Plant

Corrosion Control in Fertilizer Plant Control Room

Fertiliser plants are controlled by sensors and actuators linked via complex distributed control systems (DCS) to the control/server rooms. These complex systems are complicated webs of electronic cards and electrical components which drive fertiliser plants to run 24 x 7. This ensures enhanced quality, speed of production and cost-efficiency. Corrosion control in fertilizer plant control room is crucial to maintaining the smooth functioning of these systems.

Corrosion Affecting Smooth Fertiliser Production

Corrosion of electronic components and electrical components, due to the presence of corrosive gases, can severely disrupt the smooth operation of a fertilizer plant. This issue is particularly relevant in fertilizer plant control room corrosion, where compounds and by-products of nitrogen, phosphorus, and potassium in electrical/electronic circuits can lead to significant operational challenges.

Main Culprits for Electronic Corrosion in Fertiliser Component

Gaseous compounds are an inevitable constituent of the fertiliser production process. They are the primary reason for corrosion in electronic cards and electrical components in control and server rooms. Effective corrosion control in fertilizer plant control room requires the monitoring and regulation of these corrosive gases and by-products to prevent their entry into critical areas. The corrosive gases such as hydrogen sulphide, sulphur and nitrogen oxides, chlorine, hydrogen fluoride, ammonia and ozone are harmful not only to the machine but also to the employees. When inhaled for a prolonged duration, employees feel ill-health, vomiting, and nausea resulting in decreased efficiency and an increase in absenteeism.

Operations managers in fertiliser industries are therefore focusing on supplying clean air, free of airborne contaminants to their control rooms.

Gas Phase Filtration System – The Most Effective Way of Corrosion Control in Fertilizer Plant Control Room

Bry-Air Gas Phase Filtration Systems protect electronic equipment and devices from the threat of abrupt failures due to corrosive gases. It reduces downtime by removing corrosive gases through the process of adsorption and chemisorption. It is designed to maintain the ANSI/ISA-71.04-2013 standard, IEC standards and various other environmental standards followed by electronics manufacturers, ensuring comprehensive corrosion control in fertilizer plant control room.

These GPF systems also neutralise odourous gases and make the environment comfortable for humans, further contributing to effective corrosion control in fertilizer plant control room.

Bry-Air: A Step Ahead, Always

Bry-Air is the only Gas Phase Filtration Company in India having its own R&D and Testing Lab for granular media and chemical filters. Backed by world-class technology and systems, the laboratory is capable of testing the performance of impregnated/non-impregnated loose granular media and impregnated/non-impregnated air cleaning devices such as chemical filters, under one roof. The tests are conducted as per ISO/ASHRAE Standard 145.1 and BSR/ASHRAE Standard 145.2/ISO Standard 11155-2 guidelines. The core objectives of the tests are to assess the performance and efficiency of loose granular sorptive media and chemical filters in any particular application.

For any media replacement query related to corrosion control in fertilizer plant control room, write to us: [email protected]

Frequently Asked Questions

Why is electronic corrosion a concern in fertilizer plant control rooms?

Fertilizer plants can have corrosive gases such as ammonia (NH₃), hydrogen sulfide (H₂S), sulfur dioxide (SO₂), and nitrogen oxides (NOₓ) in or around process areas. When these contaminants enter control rooms, they can contribute to corrosion of sensitive electronic components, contacts, PCBs and control equipment.

Which gases can affect electronics in a fertilizer plant control room?

The specific contaminants depend on the process and site conditions. Ammonia, H₂S, SO₂ and NOₓ are among the gases relevant to fertilizer and process environments. A site assessment should determine the actual contaminant profile before selecting the filtration media.

How do corrosive gases reach a control room?

Corrosive gases can enter through fresh-air intakes, HVAC systems, building leakage, doors, cable penetrations and other openings. Maintaining room pressurisation alone does not remove molecular contaminants from the incoming air.

Can conventional HVAC or particulate filters prevent electronic corrosion?

Conventional particulate filters are designed primarily to remove airborne particles. Gas-phase filtration is required when the contamination problem involves gaseous molecular contaminants, which can pass through conventional particulate filtration.

What role does gas phase filtration play in protecting fertilizer plant control room electronics?

Gas phase filtration uses chemically treated or adsorbent media to remove gaseous contaminants from the air before they reach sensitive equipment. This can help reduce the corrosive load on DCS, PLC, SCADA, relay, UPS, VFD and other control electronics.

Can gas-phase filtration be integrated with the existing HVAC system?

Yes. DRISORB™ honeycomb panels are designed for integration into existing HVAC/AHU systems. This configuration uses structured sorbent media for gas-phase removal while fitting into HVAC filter arrangements.

How do you determine whether a fertilizer plant control room requires corrosion protection?

A useful starting point is to assess the ambient corrosivity and contaminant profile. Bry-Air’s GPF approach includes Corrosion Classification Coupons for a standardised 30-day exposure assessment and the Atmospheric Corrosivity Monitor (ACM) for continuous measurement of copper and silver corrosion rates.

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