Sustainable Corrosion Inhibitor Formulation for Industrial Acid Cleaning of Ferrous– and Copper-Based Alloys

Abstract This study aimed to develop a sustainable corrosion inhibitor formulation from date palm leaves, specifically tailored to simultaneously protect copper-based and ferrous-based alloys from acid corrosion encountered in industrial acid cleaning and inorganic scale removal in multistage flash desalination plants (MSF). Experimental evaluations were performed using gravimetric and electrochemical corrosion tests for various alloys, including C1020 carbon steel, Ni-resist, 316L stainless steel, 70Cu–30Ni, 90Cu–10Ni, and Ti grade 2. The testing environment consisted of a 2% hydrochloric acid (HCl) solution, and tests were conducted under hydrodynamic conditions to simulate real-world industrial scenarios. The results demonstrated that the formulated corrosion inhibitor provided excellent protection at very low concentrations, resulting in a significant reduction in corrosion rates across all tested alloys. At 0.3 wt.% concentration and at 40 °C, the developed corrosion inhibitor effectively created a protective barrier on metal surfaces. Weight loss measurements showed a protection efficiency of more than 95 % for C1020 carbon steel, 70Cu–30Ni, 90Cu–10Ni and Ti grade 2. However, lower protection efficiencies were obtained for 316L stainless steel and Ni-resist. The developed inhibitor aligns with sustainability goals and supports environmental initiatives, providing a novel, sustainable, and high-performance alternative for corrosion protection in highly acidic industrial environments.