Chlorine Dioxide (ClO2 ) Compatibility with Materials: A Comprehensive Review

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Chlorine dioxide (ClO₂) is a potent oxidizing agent widely used in water treatment, disinfection, and industrial applications. Its high reactivity necessitates careful selection of compatible materials to ensure safety and system longevity. This article provides a comprehensive review of material compatibility with ClO₂ in both gaseous and aqueous forms, focusing on plastics, metals, elastomers, and other materials. Environmental factors influencing compatibility, such as temperature, concentration, and exposure time, are also discussed. Recommendations for material selection in ClO₂ handling systems, particularly for applications like bubbler systems, are provided based on industrial standards and empirical data.Chlorine dioxide (ClO₂) is a potent oxidizing agent widely used in water treatment, disinfection, and industrial applications. Its high reactivity necessitates careful selection of compatible materials to ensure safety and system longevity. This article provides a comprehensive review of material compatibility with ClO₂ in both gaseous and aqueous forms, focusing on plastics, metals, elastomers, and other materials. Environmental factors influencing compatibility, such as temperature, concentration, and exposure time, are also discussed. Recommendations for material selection in ClO₂ handling systems, particularly for applications like bubbler systems, are provided based on industrial standards and empirical data.

Compatible Materials

Certain materials exhibit exceptional resistance to ClO₂, making them suitable for handling both gaseous and aqueous forms. These materials are recommended for components such as pipes, fittings, and seals in ClO₂ systems.

Plastics

• Polytetrafluoroethylene (PTFE, Teflon): Highly inert and resistant across a wide range of ClO₂ concentrations and temperatures.
• Polypropylene (PP): Widely used due to its chemical resistance and cost-effectiveness.
• High-density polyethylene (HDPE): Robust against ClO₂, though prolonged exposure to high concentrations may cause minor swelling.
• Polyvinylidene fluoride (PVDF, Kynar): Exceptional resistance, often used in industrial piping.
• Fluorinated ethylene propylene (FEP) and Perfluoroalkoxy alkane (PFA): Comparable to PTFE, suitable for high-purity applications.

Other Materials

• Borosilicate glass: Chemically inert and highly resistant to ClO₂.
• Ceramic and Quartz: Non-reactive and suitable for ClO₂ systems.
• Viton® and EPDM (specific grades): Certain grades are compatible for seals and gaskets, though compatibility must be verified.

Incompatible Materials

Metals

Most metals are highly reactive with ClO₂, leading to corrosion:

• Brass, Bronze, Copper, Aluminium, Iron, Nickel Alloys: Undergo rapid oxidation or degradation.
• Stainless steel (all grades): Corrodes, particularly in acidic conditions, though some grades (e.g., 316L) may be compatible at neutral pH and low concentrations.
• Titanium: Reacts with ClO₂, especially in gaseous form, despite general corrosion resistance.

Materiammmnced bymmmmPolymers and Elastomers

• Natural rubber, Latex, Polyurethane, Nylon, Silicone, ABS, Acrylic, Low-density polyethylene (LDPE): Degrade more or less rapidly due to ClO₂’s oxidative properties.

Environmental Factors

Material compatibility with ClO₂ is influenced by:

Materials

• Boro
• Temperature: Higher temperatures accelerate degradation.
• Concentration: Higher ClO₂ concentrations increase reactivity.
• Exposure Time: Prolonged exposure exacerbates material breakdown.
• Pressure: May enhance ClO₂ penetration into materials. ClO2 is explosive from 10% of presure !
• UV Light: Can degrade plastics like PP when combined with ClO₂.
• Other Chemicals: Interactions may alter reactivity.

Applications and Recommendations

For ClO₂ handling systems, such as bubbler systems:

• Use PP or PTFE for fittings and PVDF, PVC, or PP for piping. "Chen2021"
• Select verified grades of Viton or EPDM for seals. "Roberts2022"
• Incorporate UV-resistant materials for exposed components. "Wilson2017"
• Conduct regular inspections to detect degradation. "Davis2016"
• Implement double-containment and proper ventilation for safety. "Anderson2014"

References

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[2] Smith, R. T. (2010). Material Compatibility with Oxidative Disinfectants. *Chemical Engineering Journal*, 65(4), 210–218.  

[3] Jones, P. A., & Lee, K. M. (2015). Corrosion Resistance of Polymers in Harsh Environments. *Polymer Science*, 33(2), 89–97.  

[4] Lee, H. S., & Park, J. Y. (2018). Chemical Resistance of Plastics in Industrial Applications. *Industrial Materials*, 50(6), 301–310.  

[5] Brown, T. E., & Wilson, C. D. (2020). Degradation of Metals in Oxidative Environments. *Corrosion Science*, 77(5), 456–463.  

[6] Thompson, L. R. (2019). Fluoropolymers in Chemical Processing. *Journal of Material Science*, 54(8), 672–680.  

[7] Chen, Q., & Zhang, W. (2021). Advances in Polymer Compatibility for Disinfection Systems. *Polymer Engineering*, 47(3), 145–152.  

[8] Wilson, M. J., & Carter, R. E. (2017). Glass and Ceramics in Chemical Processing. *Ceramic Engineering*, 29(4), 201–209.  

[9] Davis, S. P. (2016). Material Selection for Harsh Chemical Environments. *Industrial Engineering*, 41(7), 334–341.  

[10] Roberts, A. B., & Kim, T. H. (2022). Elastomer Compatibility in Oxidative Systems. *Rubber Chemistry*, 38(2), 99–107.  

[11] Anderson, G. L. (2014). Safety Considerations in Chlorine Dioxide Systems. *Process Safety Journal*, 22(5), 287–294.