Power generation facilities operate in harsh and demanding environments, making corrosion prevention for power generation a critical concern. As a result, 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 Prevention Solutions for Power Generation Facilities
Power generation equipment operates in demanding environments where moisture, contaminants, and temperature fluctuations accelerate corrosion. Discover how ZERUST® corrosion prevention solutions help protect turbines, piping systems, electrical enclosures, and other critical assets in power plants.
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. Therefore, 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. As a result, 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
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—compatible with gearbox 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 rust preventatives.
Applications: Used for turbine rotors, metal penstocks, control valves, and gates in hydroelectric plants.
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.
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: Easily removed with ZERUST® AxxaWash™, alkaline, or solvent cleaners.
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.
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: Easily removed with ZERUST® AxxaWash™, alkaline, or 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 ZERUST® AxxaWash™, alkaline, or solvent 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.
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. Furthermore, 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.
Axxanol™ Spray-G is a sprayable rust preventative that 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 removed with ZERUST® AxxaWash™, alkaline, or solvent cleaners.
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.
Learn More About the True Cost of Corrosion
Corrosion costs industries billions each year in equipment damage, downtime, and maintenance. Discover how corrosion impacts industrial operations and why implementing a proactive corrosion prevention strategy is critical.
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.
Need Help Preventing Corrosion in Power Generation Equipment?
Corrosion can damage turbines, piping systems, electrical enclosures, and structural components across power generation facilities. Contact ZERUST® to develop a corrosion prevention strategy that protects critical equipment, reduces maintenance costs, and improves operational reliability.
Andrea Catarino specializes in translating complex corrosion prevention solutions. Her professional focus includes highlighting ZERUST®’s role in advancing sustainability by extending equipment lifespan, reducing material waste through innovative corrosion control and contributing to long-term environmental and operational efficiency.
Axxanol™ 707C VCI oil additive is a vapor-phase-only corrosion inhibitor concentrate specially designed for use with lubricating oils. Furthermore, it provides corrosion protection of metal surfaces within the void spaces of closed systems, such as internal combustion engines, transmissions, gearboxes, hydraulic systems, or other sealed, lubricated systems.
AxxaClean™ ICT®625-RR chelating rust remover is a pH-neutral immersion that recovers mildly to moderately rusted ferrous parts. Simply soak the affected parts in the ready-to-use liquid to eliminate rust on surfaces, as well as in hard-to-reach areas.
AxxaClean™ 2048 is a moderate-acting (nonhazardous) safe rust remover designed to eliminate medium rust and tarnish, even in the most hard-to-reach cracks and crevices. Additionally, it is mildly acidic (about 2.5 pH), similar to a soda drink that cleans and deoxidizes ferrous metals, brass, copper, and various alloys without leaving a gray residue.
AxxaClean™ 3048 is a rapid-acting industrial rust remover designed to eliminate heavy rust and tarnish, even in the most hard-to-reach cracks and crevices. Additionally, AxxaClean™ 3048 effectively cleans ferrous and yellow metals of rust and tarnish, and with a pH of around 1, it minimizes disposal concerns.
Axxanol™ Z-Maxx Anti-Corrosion Grease Series consists of two products, Axxanol™ Z-Maxx and Z-Maxx LV. Z-Maxx is a thick NLGI 2 grease and is also offered as a lower viscosity (LV) NLGI 0 grease that is designed for spreadability and light lubrication properties.
Vapor Capsules are portable VCI emitter diffusers containing proven ZERUST® Vapor Corrosion Inhibitors (VCI). They protect metals in hard-to-reach areas of control panels, electrical cabinets, or other enclosed spaces from corrosion, even when they are in operation. Additionally, use these VCI emitter diffusers as a supplement to other ZERUST® VCI packaging products for added protection.
Axxanol™ Spray-G is a sprayable rust preventative grease that provides the protection of a grease in the convenience of a sprayable form. It’s designed to protect metal parts, equipment, and assemblies during long-term indoor and outdoor storage and challenging overseas shipping applications where a removable coating is essential.
ICT®510-C VCI Film provides cost-effective and versatile protection against rust and corrosion damage for metal assets in shipping and storage. Additionally, it’s available in ferrous, non-ferrous, and multimetal formulations, as well as various-sized rolls, sheets, tubing, and bags.
ZAK-M22 Vapor Capsules are portable VCI capsules containing proven ZERUST® VCI technology, used to protect metals in hard-to-reach areas of control panels, electrical cabinets, or any other enclosed spaces from corrosion. Each capsule has a QR code printed on the label to facilitate scheduling its replacement schedule.
AxxaVis™ HST-10 powder additive is an effective hydrostatic testing corrosion inhibitor that treats water used to test pressure vessels and voids. It reduces hardness and deactivates ionic contaminants like chlorides found in municipal water sources, preventing rust and hard water deposits on metals.
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Hydroelectric power plants generate energy by using moving water to spin turbines, which drive electrical generators. As a result, these facilities typically include:
Wind turbines convert kinetic energy from the wind into mechanical energy, which is then used to generate electricity. These facilities consist of:
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:
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. Furthermore, these plants typically include:
