Corrosive fluids are among the most challenging media handled in industrial pumping systems. Acids, caustic chemicals, chlorides, brines and abrasive chemical mixtures can damage pump components quickly if the wrong materials are used. When corrosion begins, performance declines, maintenance costs rise and unplanned failures become far more likely.
Selecting the right pump material is the strongest first line of defense. From stainless and duplex steels and exotic alloys to polymer liners and engineered coatings, each option offers distinct advantages. The best choices will depend on factors including chemistry, temperature and operating conditions. At DXP Pacific, we help operators match pump construction to the realities of their process. This ensures more pump reliability, safety and long-term performance.
Stainless Steel: Versatile Protection for Many Corrosive Applications
Stainless steels (especially 316 and 317 grades) remain popular for moderate corrosive environments. The high chromium content builds a passive oxide layer that resists general corrosion while offering strong mechanical durability. Stainless is well suited for applications involving dilute acids, organic chemicals and mildly chlorinated water.
However, chlorides can attack stainless through pitting or crevice corrosion—especially at elevated temperatures. In brine-rich or high-chloride systems, other alloys may be required.
Duplex Stainless Steel: Higher Strength and Better Chloride Resistance
Duplex and super duplex steels combine the benefits of austenitic and ferritic structures, giving them much higher strength and improved chloride resistance. This makes duplex a great choice for high-pressure brines, seawater and aggressive chemical streams.
Advantages of duplex steels include:
- Excellent resistance to stress corrosion cracking
- High mechanical strength for demanding duty cycles
- Strong resistance to chloride-induced pitting
Duplex materials are often used in desalination, offshore water injection and chemical processing environments with high chloride content.
Exotic Alloys for Extreme Corrosion Scenarios
When fluid chemistry becomes truly aggressive, exotic alloys offer the highest level of corrosion protection. Materials such as Hastelloy, Alloy 20, Inconel and titanium are engineered to withstand strong acids and high temperatures.
These alloys excel in handling:
- Concentrated sulfuric, nitric or hydrochloric acid
- Hot chloride solutions
- Highly oxidizing or reducing environments
While exotic alloys come with a higher price tag, they deliver unmatched long-term reliability where failure simply isn’t an option.
Coatings and Liners: Cost-Effective Protection for Many Applications
In situations where full-alloy construction is not required or not economical, coatings and polymer liners offer an attractive alternative. Epoxy-based coatings, rubber linings, PTFE liners and engineered composite barriers extend pump life by shielding metal components from corrosive attack.
These solutions are particularly useful when processing abrasive slurries, mixed chemicals or corrosive wastewater streams. Coatings also help maintain smoother wetted surfaces, improving efficiency while reducing wear.
Choosing the Right Material: Key Considerations
The best material always depends on the chemistry and environment. Improper selection is one of the most common causes of premature pump failure.
Critical factors to evaluate include:
- Fluid pH, temperature and chemical concentration
- Presence of chlorides or abrasive solids
- Pressure and velocity conditions
- Required pump service life and maintenance constraints
DXP Pacific works with customers to evaluate specific process conditions, conduct corrosion compatibility reviews and recommend pump materials that deliver optimal performance and longevity.
The Right Material = Long-Term Reliability
Corrosion is one of the costliest threats to pump performance in industrial applications. Choosing the correct material—whether stainless, duplex, exotic alloys or engineered linings—ensures better uptime, lower lifecycle cost and safer operation.
With deep experience across industries and access to leading pump manufacturers, DXP Pacific helps facilities select, configure and maintain corrosion-resistant pump systems built for their toughest environments. For help with your pump and material selection needs based on your specific operation and process fluids, contact DXP Pacific today.