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Iron Corrosion: how to save industrial valves

Corrosione Ferro: come salvare le valvole industriali

Corroded metal valves? No thanks!

The term "corrosion" indicates a set of chemical-physical phenomena that lead to the degradation of metal materials by the environment to which they are exposed. But how can you protect industrial machines and make them last longer?

Iron corrosion is a natural phenomenon that can be accelerated by various factors, such as:

  1. Operating temperature
  2. Mechanical stress of the component
  3. Exercise in environments with a high concentration of oxygen
  4. Chemical affinity with any elements present in the atmosphere
  5. Composition of the base metal

Iron corrosion, for example, is an inexorable and progressive process, because rust (mainly oxidized iron Fe2O3) is a friable and porous material, which tends to flake off quickly, revealing the underlying surface and making it vulnerable to further atmospheric attacks.

Rust can also be composed of other elements, such as iron hydroxides Fe (OH) 2, free Fe ions (Fe3 + and Fe2 +) and traces of metals and derivatives, yet its reaction can be summarised as follows: 3Fe + 4H2O → Fe3O4 + 4H2.

In these cases, good prevention and careful maintenance can really make a big difference.


Corrosion of iron and lubricants

Correctly lubricated, your component can significantly increase performance, both in terms of duration and levels of operation.

It lowers temperatures, decreases wear and fatigue and limits corrosion - not to mention the advantages that you can enjoy at a company level, by limiting maintenance interventions and component repairs, which translate into substantial savings in time and money.

Take, for example, industrial valves: gate valves, globe valves, non-return valves, plug valves, ball valves ... there are many possible designs for flow regulators of intercepted fluids, for example, within chemical and petrochemical plants.

The variety in the chemical composition of the fluids intercepted by the valves requires the use of specific lubricating solutions, capable of reducing the operating torques of the valves, favouring the "sealing" effect, as with lubricated plug valves, all whilst indirectly preserving the functionality of the sealing elements.

This is why it is important to use products designed and created specifically for your needs, capable of inhibiting the corrosion of the iron of your valves, both during testing operations, as well as during transport and operation, through lubricants formulated with specific additives chosen in according to your needs.


How we solve the problem of iron corrosion

As far as industrial valves are concerned, the point of reference is a lubricating paste based on copper and graphite with high anti-wear power, suitable for sliding friction between ferrous surfaces in conditions of high pressure.

Designing the lubricating paste required a very long period of study and design, so as to encompass several characteristics:

  1. Facilitate the assembly and disassembly of mechanical couplings
  2. Prevent corrosion and protect against tribo corrosion
  3. Ensure the correct assembly of press-fit components avoiding damage
  4. Ensure perfect operation during the running-in phases
  5. Protect from wear thanks to the high resistance to high pressures, in cases of low sliding speeds
  6. Avoid stick-slip, sticking at low speeds
  7. Lubricate in emergency at high temperatures thanks to the presence of solid compounds


Do you want to know which is the best product to save your industrial valves from corrosion? We have created our own free guide on how to fight rust. Click below to download it now.


Protective lubricating fluids

Complete guide on anti-rust design


6 fundamental measures to prevent the oxidation of metals


Download the free guide

Marco Gandelli

Written by Marco Gandelli

Entrepreneur and Co-founder of Macon Research. An expert and enthusiast in lubrication mechanics and chemistry. For 15 years, having conducted thousands of analyses on electro-mechanical devices, Marco has been formulating tailor-made lubricant solutions for designers to increase efficiency, duration and control of friction. He is also a big fan of efficiency in business processes and digital marketing.

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