Microorganisms in Heat Supply Systems and Internal Corrosion of Steel Pipelines

In laboratory experiments with batch cultures of thermophilic microorganisms isolated from urban heat supply systems, the growth of sulfate-reducing, iron-oxidizing, and iron-reducing bacteria was found to accelerate the corrosion rate of the steel-3 plates used in pipelines. In the absence of bacteria and dissolved oxygen, minimal corrosion was determined. The aforementioned microorganisms, as well as sulfur-oxidizing bacteria, were found to be widespread in water and corrosion deposits in low-alloy steel pipelines (both delivery and return) of the Moscow heat networks, as well as in the corrosion deposits on the steel-3 plates in a testing unit supplied with the network water. The microorganisms were found in samples with a water pH ranging from 8.1 to 9.6 and a temperature lower than 90°C. Magnetite, lepidocrocite, goethite, and X-ray amorphous ferric oxide were the corrosion products identified on the steel-3 plates, as well as siderite, aragonite, and S⁰. The accumulation of corrosion deposits and variation in the total and local corrosion of the steel plates in a testing unit were considered in terms of the influence of microbial processes.     

微生物腐蚀及腐蚀机理研究进展

在不同的环境中,不同种类的微生物能在材料上附着繁殖,其生命活动会引起或加剧材料的腐蚀。根据种类及功能的不同,腐蚀微生物可以分为硫酸盐还原菌、硫氧化菌、产酸菌、铁氧化细菌、铁还原细菌、硝酸盐还原菌以及产粘液细菌等。微生物腐蚀几乎能使所有现用的材料受到严重影响,破坏材料的结构与性能,在建筑、运输管道、工业环境(石油化工等)以及海洋环境中造成巨大的安全隐患和财产损失。本文概述了目前发现的腐蚀相关微生物的类群和特性,以及相对应的微生物腐蚀机理,为防护和控制材料的微生物腐蚀提供理论指导。     

Chemicomicrobiological Diagnostics of Stress Corrosion Cracking of Trunk Pipelines

Samples of soil, subsoil, electrolyte, corrosion products, and protective coating were taken after excavating pipelines. The depth of stress corrosion cracking of the pipe steel was mostly related to counts of sulfate-reducing and denitrifying bacteria. In certain types of soil, crack depth correlated with the number of acid-producing microorganisms and aerobic chemoorganotrophs (saprophytes). A correlation was found between the extent of stress corrosion cracking of pipelines and the contents of mobile reduced iron, sulfides, organic carbon, and a number of other parameters of the surrounding soil.     

Chemical-microbiological diagnosis of stress-corrosive damage to pipelines]

Samples of soil, ground, electrolyte, corrosion products, and protective coating were taken after excavating pipelines. The depth of stress corrosion cracks of the pipe steel was mostly related to the numbers of sulfate-reducing and denitrifying bacteria. In certain types of soil, damage correlated with the number of acid-producing microorganisms and aerobic chemoorganotrophs (saprophytes). A correlation was found between the extent of stress-corrosion damage to pipelines and the contents of reduced iron, sulfides, and organic carbon in surrounding ground.     

The corrosion behaviour of galvanized steel in cooling tower water containing a biocide and a corrosion inhibitor

The corrosion behaviour of galvanized steel in cooling tower water containing a biocide and a corrosion inhibitor was investigated over a 10-month period in a hotel. Planktonic and sessile numbers of sulphate reducing bacteria (SRB) and heterotrophic bacteria were monitored. The corrosion rate was determined by the weight loss method. The corrosion products were analyzed by energy dispersive X-ray spectroscopy and X-ray diffraction. A mineralized, heterogeneous biofilm was observed on the coupons. Although a biocide and a corrosion inhibitor were regularly added to the cooling water, the results showed that microorganisms, such as SRB in the mixed species biofilm, caused corrosion of galvanized steel. It was observed that Zn layers on the test coupons were completely depleted after 3?months. The Fe concentrations in the biofilm showed significant correlations with the weight loss and carbohydrate concentration (respectively, p?<?0.01 and p?<?0.01).     

Biofouling and microbial corrosion problem in the thermo-fluid heat exchanger and cooling water system of a nuclear test reactor

This article discusses aspects of biofouling and corrosion in the thermo-fluid heat exchanger (TFHX) and in the cooling water system of a nuclear test reactor. During inspection, it was observed that >90% of the TFHX tube bundle was clogged with thick fouling deposits. Both X-ray diffraction and Mössbauer analyses of the fouling deposit demonstrated iron corrosion products. The exterior of the tubercle showed the presence of a calcium and magnesium carbonate mixture along with iron oxides. Raman spectroscopy analysis confirmed the presence of calcium carbonate scale in the calcite phase. The interior of the tubercle contained significant iron sulphide, magnetite and iron-oxy-hydroxide. A microbiological assay showed a considerable population of iron oxidizing bacteria and sulphate reducing bacteria (10⁵ to 10⁶ cfu g^?1 of deposit). As the temperature of the TFHX is in the range of 45–50°C, the microbiota isolated/assayed from the fouling deposit are designated as thermo-tolerant bacteria. The mean corrosion rate of the CS coupons exposed online was ～2.0 mpy and the microbial counts of various corrosion causing bacteria were in the range 10³ to 10⁵ cfu ml^?1 in the cooling water and 10⁶ to 10⁸ cfu ml^?1 in the biofilm.     

Survival of Microorganisms in a Rock Bed Under Conditions Simulating Solar Heat Storage

A laboratory-scale unit containing about 360 kg of washed river gravel was designed to [ill] the use of rocks for heat storage. The unit was operated under varying conditions of temperature, relative humidity, and the addition of volatile nutrients over a 4-month period. Effluent air and rock surfaces were monitored for the presence of microorganisms. After 2 weeks, virtually no microorganisms were detected in the effluent air except when dry soil or compost was added as the inoculum. A small number of heat-resistant bacteria, but no fungi, were found to survive on the rock surfaces. Microorganisms isolated were either sporeforming bacteria or actinomycetes closely resembling Thermoactinomyces vulgaris. Microbial colonization of rock beds used for solar heat storage does not appear likely under routine operation.     

Automated measurement and quantification of heterotrophic bacteria in water samples based on the MPN method

Quantification of heterotrophic bacteria is a widely used measure for water analysis. Especially in terms of drinking water analysis, testing for microorganisms is strictly regulated by the European Drinking Water Directive, including quality criteria and detection limits. The quantification procedure presented in this study is based on the most probable number (MPN) method, which was adapted to comply with the need for a quick and easy screening tool for different kinds of water samples as well as varying microbial loads. Replacing tubes with 24-well titer plates for cultivation of bacteria drastically reduces the amount of culture media and also simplifies incubation. Automated photometric measurement of turbidity instead of visual evaluation of bacterial growth avoids misinterpretation by operators. Definition of a threshold ensures definite and user-independent determination of microbial growth. Calculation of the MPN itself is done using a program provided by the US Food and Drug Administration (FDA). For evaluation of the method, real water samples of different origins as well as pure cultures of bacteria were analyzed in parallel with the conventional plating methods. Thus, the procedure described requires less preparation time, reduces costs and ensures both stable and reliable results for water samples.     

Substrate Availability,pH, and Temperature Influence Methanogenesis and Mild Steel Corrosion

Solid deposits of corroded pipelines in the Niger Delta were analyzed both chemically and microbiologically. The addition of substrate, especially acetate, significantly stimulated the methane production ranging from 0.85 to 1.60 mmole compared with 0.65 mmole of the control. Acetotrophic and hydrogenotrophic methanogens had their optimal methane production and corrosion rate at pH 5.5. All three types of methanogens produced the most methane at 37°C. Methane production by methanogens correlated strongly with corrosion rate. Pyrosequencing surveys show dominance of acetotrophic, hydrogenotrophic, and methylotrophic methanogens in the samples with no significant presence of sulfate-reducing bacteria (SRB), most likely due to the presence of the biocide, tetrakis-hydroxymethyl phosphonium sulfate. Our study shows that methanogens were one possible cause of pipeline failures in samples from the Niger Delta without the syntrophic association with SRB.     

Oil field microorganisms cause highly localized corrosion on chemically inhibited carbon steel

Carbon steel pipelines, a means for crude oil transportation, occasionally experience highly localized perforation caused by microorganisms. While microorganisms grown in laboratory culture tend to corrode steel specimens unevenly, they rarely inflict a corrosion morphology consistent with that of pipelines, where centimetre-sized corrosion features are randomly distributed within vast stretches of otherwise pristine metal surface. In this study, we observed that corrosion inhibitors (CIs), widely used for the control of acid gas (H₂S, CO₂) corrosion in oil fields, also affect microbial growth and activity. Inhibited carbon steel resisted biofilm formation and underwent negligible corrosion (< 0.002 mm Fe⁰ year⁻¹), despite 15 months of exposure to oil field waters harbouring a diverse microbiome. In contrast, physical scavenging of CI in these waters led to severe and highly localized corrosion (up to 0.93 mm Fe⁰ year⁻¹) underneath biofilms dominated by methanogenic archaea and sulfate-reducing bacteria. A sharp decline in CI concentration, as well as its active components, quaternary ammonium compounds (QACs), correlated with microbial sulfidogenesis. CIs are ubiquitously present in oil field waters and play an underappreciated role in microbial corrosion mitigation. Physical and biological scavenging of CIs may create local differences in steel inhibition effectiveness and thus result in highly localized corrosion.     

Effect of W–TiO2 composite to control microbiologically influenced corrosion on galvanized steel

Microorganisms tend to colonize on solid metal/alloy surface in natural environment leading to loss of utility. Microbiologically influenced corrosion or biocorrosion usually increases the corrosion rate of steel articles due to the presence of bacteria that accelerates the anodic and/or cathodic corrosion reaction rate without any significant change in the corrosion mechanism. An attempt was made in the present study to protect hot-dip galvanized steel from such attack of biocorrosion by means of chemically modifying the zinc coating. W–TiO₂ composite was synthesized and incorporated into the zinc bath during the hot-dipping process. The surface morphology and elemental composition of the hot-dip galvanized coupons were analyzed by scanning electron microscopy and energy dispersive X-ray spectroscopy. The antifouling characteristics of the coatings were analyzed in three different solutions including distilled water, seawater, and seawater containing biofilm scrapings under immersed conditions. Apart from electrochemical studies, the biocidal effect of the composite was evaluated by analyzing the extent of bacterial growth due to the presence and absence of the composite based on the analysis of total extracellular polymeric substance and total biomass using microtiter plate assay. The biofilm-forming bacteria formed on the surface of the coatings was cultured on Zobell Marine Agar plates and studied. The composite was found to be effective in controlling the growth of bacteria and formation of biofilm thereafter.     

Variation in sessile microflora as function of flow velocity on coupons exposed to seawater

The variability of several groups of microorganisms on AISI 1020 carbon steel coupons as a function of seawater velocity in a water circulation loop was investigated. The metal probes as well as electrodes were fixed onto ducts connected to a 35l capacity tank, in order to study both biofilm formation and some electrochemical parameters. The experiments were carried out at different seawater velocities. The technique of the most probable number was used to enumerate bacterial aerobes and anaerobes as well as sulphate-reducing bacteria and iron-reducing bacteria. Fungi were quantified by counting the number of colony forming units. At velocities of 3.6 cm/s, which correspond to a laminar flow, the numbers of aerobic and anaerobic bacteria attached to the metal surfaces reached a maximum. Such values were markedly reduced at velocities of 17.4–26.0 and 34.8 cm/s. The corrosion rate at the start of the process was 1.4 mm/year, decaying to levels of about 0.4–0.6 mm/year over the experimental period. Analysis of loss of carbon steel coupons mass after 35 days of the process indicated a mean corrosion rate of approximately 2 mm/year. This revised version was published online in November 2006 with corrections to the Cover Date.     

Biofilm formation in water cooling systems

Biofilm formation on stainless steel samples immersed in cooling water has been evaluated by exposing metal samples to cooling seawater for 30 days. Anaerobic bacteria were then at 1.6 × 10⁶/cm², with sulphate-reducing species predominating. Aerobic bacteria and fungi were 2600 and 140/cm², respectively. After 60 days, numbers of aerobic microorganisms remained constant whereas the count of anaerobic microorganisms had increased to 1.8×10⁹/cm². Scanning electron microscopy showed the presence of morphologically different microorganisms in deposits and as a mucilaginous net. No signs of corrosion were detected on the stainless steel surface.The authors are with the Departamento de Engenharia Bioquimica Centro de Tecnologia, Bloco E. Universidade Federal do Rio de Janeiro Ilha do Fundão, 21941-900 Rio de Janeiro, Brazil     

Characterization of bacterial community associated to biofilms of corroded oil pipelines from the southeast of Mexico

Microbial communities associated to biofilms promote corrosion of oil pipelines. The community structure of bacteria in the biofilm formed in oil pipelines is the basic knowledge to understand the complexity and mechanisms of metal corrosion. To assess bacterial diversity, biofilm samples were obtained from X52 steel coupons corroded after 40 days of exposure to normal operation and flow conditions. The biofilm samples were directly used to extract metagenomic DNA, which was used as template to amplify 16S ribosomal gene by PCR. The PCR products of 16S ribosomal gene were also employed as template for sulfate-reducing bacteria (SRB) specific nested-PCR and both PCR products were utilized for the construction of gene libraries. The V3 region of the 16S rRNA gene was also amplified to analyse the bacterial diversity by analysis of denaturing gradient gel electrophoresis (DGGE). Ribosomal library and DGGE profiles exhibited limited bacterial diversity, basically including Citrobacter spp., Enterobacter spp. and Halanaerobium spp. while Desulfovibrio alaskensis and a novel clade within the genus Desulfonatronovibrio were detected from the nested PCR library. The biofilm samples were also taken for the isolation of SRB. Desulfovibrio alaskensis and Desulfovibrio capillatus, as well as some strains related to Citrobacter were isolated. SRB consists in a very small proportion of the community and Desulfovibrio spp. were the relatively abundant groups among the SRB. This is the first study directly exploring bacterial diversity in corrosive biofilms associated to steel pipelines subjected to normal operation conditions.     

Corrosion of metals in natural waters influenced by manganese oxidizing microorganisms

Case histories and proposed mechanisms formicrobiologically influenced corrosion of metals andalloys by metal depositing microorganisms arereviewed. Mechanisms with indirect participation ofthese microorganisms, usually iron- and manganeseoxidizing species, are distinguished from anothermechanism which accounts specifically for theelectrochemical properties of deposits containingoxides and hydroxides of Mn in higher oxidationstates. The possible influence of such deposits whichwere formed microbiologically is evaluated. Theevaluation is based on the principles ofelectrochemical corrosion of metals and on theelectrochemical properties of Mn^3+/4+- compounds.After briefly reviewing the microbiologicalMn-oxidation, experimental evidence for the predictedcorrosion by such deposits is provided and a model formicrobiologically influenced corrosion by manganeseoxidizing microorganisms is proposed for stainlesssteel. Possible consequences of the model andpractical aspects of such a corrosion are discussed.     

Corrosion behavior of carbon steel in the presence of two novel iron-oxidizing bacteria isolated from sewage treatment plants

In this work, two novel iron oxidizing bacteria (IOB), namely Gordonia sp. MZ-89 and Enterobacter sp. M01101, were isolated from sewage treatment plants and identified by biochemical and molecular methods. Then, microbially influenced corrosion (MIC) of carbon steel in the presence of these bacteria was investigated. The electrochemical techniques such as potentiodynamic polarization measurements and electrochemical impedance spectroscopy (EIS) were used to measure the corrosion rate and observe the corrosion mechanism. The results showed that the existence of these microorganisms decreased the corrosion potential and enhanced the corrosion rate. Scanning electron microscopy (SEM) images revealed the ground boundary attacks and pitting on carbon steel samples in the presence of these bacteria after polarization. Corrosion scales were identified with X-ray diffraction (XRD). It was demonstrated that these bacteria can greatly affect the crystalline phase of corrosion products that also confirmed by SEM results. It was inferred that these bacteria were responsible for the corrosion of carbon steel, especially in the form of localized corrosion.     

纤维素分解菌对不同纤维素类物质的分解作用

经过CMC平板、滤纸液化和摇瓶培养试验 ,发现 6株菌中 ,产黄纤维单胞菌 (CellulomonasFlav igena)和康氏木霉 (Trichodermakonigii)分解纤维素类物质的能力比较强 ,对来源不同的纤维素类物质分解能力差异很大 ;真菌与细菌一起接种时 ,分解纤维素类物质的速度明显高于其中任何一个单一菌株 ,说明纤维素类物质的分解需要多种微生物的联合作用     

Effect of sodium bisulfite injection on the microbial community composition in a brackish-water-transporting pipeline

Pipelines transporting brackish subsurface water, used in the production of bitumen by steam-assisted gravity drainage, are subject to frequent corrosion failures despite the addition of the oxygen scavenger sodium bisulfite (SBS). Pyrosequencing of 16S rRNA genes was used to determine the microbial community composition for planktonic samples of transported water and for sessile samples of pipe-associated solids (PAS) scraped from pipeline cutouts representing corrosion failures. These were obtained from upstream (PAS-616P) and downstream (PAS-821TP and PAS-821LP, collected under rapid-flow and stagnant conditions, respectively) of the SBS injection point. Most transported water samples had a large fraction (1.8% to 97% of pyrosequencing reads) of Pseudomonas not found in sessile pipe samples. The sessile population of PAS-616P had methanogens (Methanobacteriaceae) as the main (56%) community component, whereas Deltaproteobacteria of the genera Desulfomicrobium and Desulfocapsa were not detected. In contrast, PAS-821TP and PAS-821LP had lower fractions (41% and 0.6%) of Methanobacteriaceae archaea but increased fractions of sulfate-reducing Desulfomicrobium (18% and 48%) and of bisulfite-disproportionating Desulfocapsa (35% and 22%) bacteria. Hence, SBS injection strongly changed the sessile microbial community populations. X-ray diffraction analysis of pipeline scale indicated that iron carbonate was present both upstream and downstream, whereas iron sulfide and sulfur were found only downstream of the SBS injection point, suggesting a contribution of the bisulfite-disproportionating and sulfate-reducing bacteria in the scale to iron corrosion. Incubation of iron coupons with pipeline waters indicated iron corrosion coupled to the formation of methane. Hence, both methanogenic and sulfidogenic microbial communities contributed to corrosion of pipelines transporting these brackish waters.     

Destruction of concrete by nitrification

Summary Nitrification was studied, using samples of asbestos concrete plates and water, both taken from a cooling tower, in which ammonia-containing water had been circulated for several years. Almost the entire nitrifying activity and the majority of autotrophic nitrifying bacteria were found to be located in the coating, covering the asbestos concrete plates. When sprinkled over these plates, the H⁺-concentration of such ammonia-containing water increased from neutrality to about pH 5.3 and this pH was maintained as long as nitrification was feasible. Death of microorganisms and lack of either ammonia or oxygen caused a rapid decrease of H⁺-concentration, which was obviously due to concrete destruction. The temporary acidification observed in the medium resulted from both acid-producing microbial nitrification and acid consuming concrete dissolution, with both reactions counteracting each other. The amount of nitric acid required to maintain a low pH in presence of concrete was determined by automatic titration. The obtained result indicated that considerable amounts of nitric acid might have been formed in the cooling system, which could well account for the observed damage.     

Characterization of microbial communities in gas industry pipelines

Culture-independent techniques, denaturing gradient gel electrophoresis (DGGE) analysis, and random cloning of 16S rRNA gene sequences amplified from community DNA were used to determine the diversity of microbial communities in gas industry pipelines. Samples obtained from natural gas pipelines were used directly for DNA extraction, inoculated into sulfate-reducing bacterium medium, or used to inoculate a reactor that simulated a natural gas pipeline environment. The variable V2-V3 (average size, 384 bp) and V3-V6 (average size, 648 bp) regions of bacterial and archaeal 16S rRNA genes, respectively, were amplified from genomic DNA isolated from nine natural gas pipeline samples and analyzed. A total of 106 bacterial 16S rDNA sequences were derived from DGGE bands, and these formed three major clusters: beta and gamma subdivisions of Proteobacteria and gram-positive bacteria. The most frequently encountered bacterial species was Comamonas denitrificans, which was not previously reported to be associated with microbial communities found in gas pipelines or with microbially influenced corrosion. The 31 archaeal 16S rDNA sequences obtained in this study were all related to those of methanogens and phylogenetically fall into three clusters: order I, Methanobacteriales; order III, Methanomicrobiales; and order IV, Methanosarcinales: Further microbial ecology studies are needed to better understand the relationship among bacterial and archaeal groups and the involvement of these groups in the process of microbially influenced corrosion in order to develop improved ways of monitoring and controlling microbially influenced corrosion.