Mathematical model of electrochemical corrosion of current-conducting elements considering local environmental parameters in livestock farms

The high corrosion rate of electrical equipment in livestock facilities represents a critical operational challenge. To predict the residual service life of such equipment, it is necessary to account for the spatiotemporal heterogeneity of ammonia and hydrogen sulfide concentrations, as well as variations in temperature and humidity. The study aimed to develop a comprehensive mathematical model for predicting the electrochemical corrosion rate of current-carrying components (copper and aluminum) as a function of changing indoor climate parameters. The proposed model is based on a system of equations that integrates electrochemical, electrical, and thermal processes. For model verification, an experimental setup was employed comprising a climate chamber, a precision control system for temperature and humidity, a gas dispenser, and an OKA-T-H₂S-NH₃ gas analyzer. Validation of the model was performed by comparing calculated corrosion rate values with experimental data that were not used during model calibration. Input data for the model included the physicochemical properties of the materials and the corrosion rates of copper and aluminum obtained under varying conditions within the climate chamber: ammonia concentrations ranging from 0 to 50 ppm, hydrogen sulfide concentrations from 0 to 20 ppm, temperatures from 20 to 30°C, and relative humidity levels from 70 to 90%. The results established that increasing relative humidity from 70% to 90% leads to an increase in corrosion rate by a factor of 1.6 to 2.3, depending on the material and the composition of the gaseous environment. The corrosion rate of copper was found to be particularly sensitive to hydrogen sulfide concentration, with a reaction order of 0.85, while that of aluminum was most sensitive to ammonia concentration, with a reaction order of 0.72. At ammonia concentrations ranging from 0 to 50 ppm and a background hydrogen sulfide concentration of 10 ppm, the corrosion rate of copper increases from 0.11 to 0.26 mm/year, and that of aluminum increases from 0.105 to 0.225 mm/year. For hydrogen sulfide concentrations between 0 and 20 ppm, with a background ammonia concentration of 20 ppm, the corrosion rate of copper varies from 0.16 to 0.35 mm/year, while that of aluminum varies from 0.063 to 0.142 mm/year. A coefficient of determination (R²) of 0.92 indicates a high level of agreement between the model and experimental data. The developed model will enable the determination of residual service life of electrical equipment, the prediction of contact resistance increase, and the transition to a predictive maintenance system.

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