Corrosion Prevention for Power Generation: Protecting Critical Equipment

Power generation facilities operate in harsh and demanding environments, making corrosion prevention for power generation a critical concern. Components in biomass energy plants, hydroelectric power plants, solar power energy systems, geothermal facilities, and wind power systems face continuous exposure to moisture, fluctuating temperatures, airborne contaminants, and harsh chemicals. If left unchecked, corrosion can lead to equipment failure, unplanned downtime, safety risks, and expensive repairs.

ZERUST® provides corrosion prevention solutions to protect critical power generation equipment, including gearboxes, turbines, heat exchangers, piping systems, and electrical enclosures. Furthermore, by integrating Vapor Corrosion Inhibitor (VCI) technology, anti-corrosion greases, rust removers, and protective coatings, ZERUST® helps maximize equipment lifespan, enhance operational efficiency, and reduce maintenance costs.

Corrosion Challenges in Power Generation Facilities

Corrosion in power generation facilities occurs due to a variety of environmental and operational factors, such as:

• High humidity and moisture exposure – Leads to rust, oxidation, and pitting corrosion.
• Temperature fluctuations – Causes condensation, which accelerates metal degradation.
• Chemical exposure – Sulfuric acid, carbonic acid, and hydrogen sulfide contribute to aggressive corrosion.
• Electrical currents – Induce galvanic corrosion when dissimilar metals are in contact.
• Salt-laden air and UV radiation – Degrade metal structures and mounting hardware in solar power and wind energy systems.

Each type of power generation facility faces unique corrosion threats due to environmental conditions, equipment exposure, and operational processes. Below are some of the key components at risk and how ZERUST® Corrosion Prevention for Power Generation solutions provide effective protection.

Hydroelectric Power Plants: Preventing Water-Induced Corrosion

Hydroelectric power plants generate energy by using moving water to spin turbines, which drive electrical generators. These facilities typically include:

• Dams and reservoirs to store water.
• Penstocks (large pipes) to direct water to turbines.
• Turbines and rotors that convert water energy into mechanical power.
• Control systems that regulate power output.

Since hydroelectric power plants are constantly exposed to water, high humidity, and sediment buildup, metal components experience severe corrosion risks. Moreover, dissolved oxygen, minerals, and fluctuating pH levels accelerate pitting, crevice, and galvanic corrosion, weakening structures.

Common Corrosion Issues in Hydroelectric Power Plants

• Turbines & Rotors – Erosion-corrosion and cavitation degrade turbine blades, reducing efficiency.
• Gearboxes & Bearings – Water ingress leads to oil contamination, causing internal rust and mechanical failure.
• Control Valves & Gates – Fluctuating water pressure leads to pitting corrosion, resulting in leaks.
• Metal Piping & Penstocks – Sediment and mineral deposits promote internal pipe corrosion, increasing failure risks.

ZERUST® Solutions for Hydroelectric Power Facilities:

	Axxanol™ 707C VCI Oil Additive Axxanol™ 707C is a vapor-phase corrosion inhibitor (VCI) oil additive designed to protect the internal surfaces of closed systems, such as gearboxes, engines, and hydraulic systems. It prevents corrosion in void spaces left unprotected when lubricating oils drain away during storage or shutdowns. Protection: Provides up to 2 years‡ of corrosion protection in closed, lubricated systems. Applications: Ideal for hydroelectric power plant gearboxes, bearings, and hydraulic systems, preventing rust in areas exposed to humidity and water ingress. Removal: No removal required—remains compatible with engine and hydraulic oils when used as directed.
	AxxaClean™ Rust Removers AxxaClean™ rust removers restore corroded turbines, valves, and pipelines by removing rust without damaging the base material. Protection: Removes rust and prepares metal surfaces for protective coatings. Applications: Used for turbine rotors, metal penstocks, control valves, and gates in hydroelectric plants. Removal: Rinse with high-quality water or a ZERUST® AxxaVis™ HST-10 solution for optimal performance.
	Axxanol™ Z-Maxx Grease Axxanol™ Z-Maxx is a heavy-duty anti-corrosion grease that protects exposed metal components from high moisture and humid conditions. Protection: Shields outdoor assets for up to one year‡ and indoor assets for up to three years‡. Applications: Ideal for exposed metal parts in hydroelectric facilities, including turbine bearings and piping connections. Removal: Easily removed using ZERUST® AxxaWash™ or commercial cleaners.

Wind Power Systems: Protecting Components from Atmospheric Corrosion

Wind turbines convert kinetic energy from the wind into mechanical energy, which is then used to generate electricity. These facilities consist of:

• Turbine blades that capture wind energy.
• Gearboxes & bearings that transmit rotational energy.
• Electrical cabinets & control systems that regulate output.

Common Corrosion Issues in Wind Turbines

• Nacelle & Gearbox Components – Moisture ingress leads to bearing and gear corrosion, reducing turbine efficiency.
• Electrical Cabinets & Control Systems – Humidity and condensation cause rust, leading to shorts and equipment failures.
• Fasteners & Structural Components – Bolts, brackets, and frames experience salt spray corrosion, weakening the overall structure.

ZERUST® Solutions for Wind Turbines:

	ZERUST® Vapor Capsules These self-contained VCI diffusers emit corrosion-inhibiting vapors inside electrical cabinets, nacelles, and control systems, preventing rust on sensitive components. Protection: Provides up to 2 years‡ of corrosion protection in sealed enclosures. Applications: Used in wind turbine electrical cabinets, nacelle control boxes, and wiring enclosures. Installation: Simply peel and stick inside an enclosure—no power or maintenance required.
	ZERUST® Axxanol™ Z-Maxx Grease Axxanol™ Z-Maxx offers superior corrosion resistance for bearings and exposed fasteners, even in salt-laden air environments. Protection: Prevents rust in extreme wind farm conditions, offering up to 1 year‡ of outdoor protection. Applications: Used for wind turbine bearing housings and exposed metal structures. Removal: Easily removed with ZERUST® AxxaWash™ or solvent cleaners.
	ZERUST® Axxanol™ Spray-G This sprayable rust preventative grease provides an easy-to-apply protective layer for hard-to-reach areas in wind turbines. Protection: Offers up to 1 year‡ of outdoor protection and up to 2 years‡ indoors. Applications: Ideal for turbine hubs, exposed fasteners, and structural brackets. Removal: Can be easily wiped or washed off when components are ready for maintenance.
	ICT®510-C VCI Film ZERUST® ICT®510-C VCI Film is a versatile, cost-effective corrosion prevention solution for power generation designed for wind turbine components in transit and storage. Protection: Provides long-term corrosion protection by diffusing odorless, non-toxic VCI molecules onto metal surfaces. Applications:  Manufacturers use ICT®510-C VCI Film to wrap wind turbine components before shipping, ensuring protection from moisture and contaminants during long-haul transportation. Ideal for spare parts and critical turbine components stored on-site, preventing corrosion before installation or maintenance. Available in rolls, sheets, tubing, and bags, making it adaptable to various packaging needs. Removal: Once removed from packaging, VCI molecules dissipate, allowing immediate painting, welding, or further processing without additional cleaning.

Solar Power Systems: Preventing Corrosion on Structural Components

Solar power systems generate energy by converting sunlight into electricity through photovoltaic (PV) cells. These facilities include:

• Solar power panels & PV arrays that capture sunlight.
• Mounting hardware & metal frames that support the panels.
• Battery storage systems that store generated energy.

Common Corrosion Issues in Solar Power Facilities

• PV Panel Frames & Mounting Hardware: UV exposure and moisture accelerate oxidation, weakening the structure.
• Grounding Components & Electrical Connections: Humidity causes electrical contact corrosion, reducing efficiency.
• Battery Storage Systems: Corrosive gases degrade battery terminals and enclosures, leading to failure.

ZERUST® Solutions for Solar Power Facilities:

	ZERUST® Axxanol™ Z-Maxx Grease Axxanol™ Z-Maxx anti-corrosion grease shields solar power panel frames, mounting hardware, and electrical connectors from environmental exposure. Protection: Provides up to 3 years‡ of indoor protection and 1 year‡ in outdoor conditions. Applications: Applied to solar panel mounting systems, grounding components, and electrical enclosures. Removal: Can be wiped off or cleaned using ZERUST® AxxaWash™ solvent cleaners
	ZERUST® Axxanol™ Spray-G Axxanol™ Spray-G is a sprayable rust preventative that protects solar panel support structures and fasteners. Protection: Shields metal support components for up to 1 year‡ outdoors. Applications: Used for solar panel mounting frames, exposed metal brackets, and junction boxes. Removal: Easily removed with solvent or alkaline cleaners.
	ZERUST® Vapor Capsules These compact VCI Emitter Diffusers prevent rust and corrosion in battery storage systems and electrical enclosures. Protection: Protects sensitive electrical components for up to 2 years‡. Applications: Used in solar energy battery storage enclosures and panel junction boxes. Installation: Simple peel-and-stick application inside the enclosure.

Biomass Energy Facilities: Combatting Acidic and High-Temperature Corrosion

Biomass energy plants generate electricity by burning organic materials such as wood chips, agricultural waste, and municipal solid waste. The combustion process produces steam, which drives turbines to generate electricity. Biomass energy facilities include:

• Fuel storage and processing systems to prepare organic material for combustion.
• Boilers and heat exchangers to convert water into steam.
• Steam turbines and generators to produce electricity.
• Flue gas treatment systems to control emissions.

Because biomass energy plants burn organic material, they generate high levels of corrosive byproducts, including sulfuric acid, acetic acid, and carbonic acid. Furthermore, these aggressive compounds weaken metal surfaces, leading to faster degradation of boilers, pipes, and heat exchangers.

Common Corrosion Issues in Biomass Energy Facilities

• Boilers & Heat Exchangers: Exposure to sulfuric and acetic acid leads to rapid metal degradation and reduced thermal efficiency.
• Piping & Steam Generation Systems: Carbonic acid formation from condensation corrodes internal pipe walls, increasing failure risks.
• Control Panels & Electrical Systems: Airborne particles and moisture cause rust on circuit boards and enclosures, leading to equipment malfunctions.

ZERUST® Solutions for Biomass Energy Facilities:

	ZAK-M22 Vapor Capsules These VCI capsules neutralize acidic contaminants in control panels and electrical enclosures. Protection: Offers up to 2 years‡ of protection against rust and acid damage. Applications: Used in biomass facility control rooms, PLC cabinets, and instrumentation enclosures. Installation: Easy adhesive-backed installation inside enclosures.
	Rust Preventative Coatings for Boilers & Pipes ZERUST® Rust Preventative Coatings shield biomass energy plant components from acidic corrosion and high-heat exposure. Protection: Long-term barrier against sulfuric and acetic acid exposure. Applications: Applied to boilers, pressure vessels, heat exchangers, and piping systems. Removal: Can be recoated or removed with industrial cleaning solutions.
	AxxaVis™ HST-10 This hydrostatic testing corrosion inhibitor additive prevents internal pipe corrosion during hydrostatic pressure testing. Protection: Prevents rust formation inside biomass facility pipelines. Applications: Used in steam generation and feedwater piping. Removal: Does not require removal, as it is designed for hydrostatic testing applications.

Geothermal Power Plants: Managing Corrosion in Extreme Conditions

Geothermal power plants extract heat from the Earth to generate electricity. High-pressure steam or hot water from underground reservoirs is used to drive turbines, which then generate power. These plants typically include:

• Production wells that bring geothermal fluids to the surface.
• Turbines & separators to convert heat into mechanical energy.
• Heat exchangers & condensers that optimize energy transfer.
• Cooling towers to remove excess heat.

Because geothermal fluids are often rich in dissolved salts, hydrogen sulfide (H₂S), and carbon dioxide (CO₂), they accelerate metal degradation through pitting, crevice corrosion, and sulfide stress cracking. Additionally, high mineral content causes scaling, which further exacerbates corrosion damage.

Common Corrosion Issues in Geothermal Power Plants

• Heat Exchangers & Well Casings: Exposure to high-salinity water and dissolved gases accelerates metal thinning and pitting corrosion.
• Turbines & Separators: Hydrogen sulfide (H₂S) causes sulfide stress cracking, leading to metal embrittlement and premature failure.
• Cooling Towers & Condensers: Constant wet/dry cycles promote galvanic corrosion, weakening structural integrity.

ZERUST® Solutions for Geothermal Facilities:

	AxxaVis™ HST-10 AxxaVis™ HST-10 protects geothermal well casings and pipelines during hydrostatic pressure tests. Protection: Prevents rust caused by dissolved gases and high-salinity geothermal fluids. Applications: Used in high-temperature well casings, steam transport pipes, and geothermal heat exchangers. Removal: No removal required—remains compatible with existing fluid systems.
	ICT®510-OPS Outdoor Preservation Film This 8-mil high-strength VCI shrink film shields turbines, separators, and heat exchangers from corrosion. Protection: Provides UV and weather-resistant corrosion protection for up to 3 years‡. Applications: Used for geothermal turbines, condensers, and heat exchangers during outdoor storage. Installation: Requires heat-shrinking for a tight, protective seal.
	ZERUST® Axxanol™ Spray-G Axxanol™ Spray-G forms a protective grease barrier on steam-exposed surfaces, preventing high-temperature corrosion. Protection: Shields metal components from sulfur corrosion and scaling. Applications: Used for geothermal steam turbines, separator housings, and metal piping joints. Removal: Easily cleaned off with solvent-based cleaners when maintenance is required.

The Cost of Corrosion

When it comes to Corrosion Prevention for the Power Generation industry, ZERUST® is a trusted partner for renewable energy operations worldwide, ensuring the reliability, safety, and sustainability of power generation systems. Furthermore, if you’re curious to calculate the cost of corrosion in your facility, explore our corrosion cost calculator and discover how ZERUST® can make a difference.

The cost of corrosion in renewable energy facilities is significant, with an estimated annual loss of $27.7 billion in 2017, according to the white paper “Corrosion Reduction in Power Distribution” by the Institute of Electrical and Electronics Engineers (IEEE). This figure does not include structural integrity issues or safety hazards, further highlighting the importance of effective corrosion management strategies to avoid such consequences of corrosion.

ZERUST® Corrosion Prevention for Power Generation

ZERUST®/EXCOR® offers a comprehensive suite of corrosion management solutions designed to address these challenges across diverse energy systems, including biomass energy, hydroelectric power, and solar power. From vapor corrosion inhibitors (VCIs) and cleaning solutions to protective coatings, shrink films, and chemical inhibitors, ZERUST® provides tailored strategies to protect both ferrous and non-ferrous, as well as combined metal components, such as electric panels, in a wide variety of environmental conditions. Furthermore, by safeguarding critical components, ZERUST® helps facilities operate more efficiently, reduce maintenance costs, and extend equipment lifespan.