Case Study: Corrosion Analysis and Air Quality Monitoring in a Chemical Industry Laboratory

Industry: Chemical Manufacturing and Research

Challenge:

A leading chemical industry laboratory in India observed unusual corrosion on laboratory-grade stainless steel furniture. The issue raised concerns regarding ambient air quality, humidity, and potential presence of corrosive gases or water vapor within the lab environment.The customer sought a diagnostic and monitoring solution that could identify root causes, quantify contributing environmental factors, and help prevent future occurrences.

Solution:

Ai-DEA Labs implemented a focused Indoor Air Quality (IAQ) monitoring solution, complemented by selected fixed sensors to measure critical parameters influencing corrosion. As this was a brownfield implementation, the system was designed to integrate with existing fixed sensors, minimizing additional infrastructure cost and ensuring seamless deployment.

The solution delivered:

• Continuous monitoring of air quality, humidity, temperature, and potential corrosive gases

• Data correlation between environmental parameters and corrosion patterns

• Real-time dashboards and alarm notifications for threshold breaches

• Cloud-based data logging for trend analysis and long-term insight generation

• Compatibility with local and central audio-visual alert systems (buzzers and LED indicators) for area-specific environmental warnings

  
  

Implementation:

The engagement involved 2 person-days of site study to understand the laboratory conditions and equipment placement.A total of 8 monitoring devices were deployed across sensitive laboratory zones.The entire implementation — including configuration, calibration, testing, and user training — was completed within two months.

Results:

• Identification of specific environmental contributors to the observed corrosion issue

• Actionable insights derived from IAQ and sensor data analysis

• Ongoing monitoring enabling early detection of corrosive environmental trends

• Customer initiated corrective measures based on Ai-DEA Labs’ data-driven insights

• Strengthened preventive maintenance strategy for future corrosion control

Key Takeaway:

By integrating IAQ monitoring and advanced analytics, Ai-DEA Labs helped the customer uncover the root causes of material degradation. The insights gained have paved the way for improved air management, material longevity, and laboratory safety within a challenging chemical environment.