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Degassing

Degassing is the deliberate removal of dissolved, adsorbed, or trapped gases from liquids, solids, melts, or other materials, typically via vacuum, thermal, or mechanical methods, to enhance purity, prevent structural defects like porosity or bubbles, and enable downstream processes.^[1]^[2] In chemistry and water treatment, it targets dissolved gases such as oxygen and carbon dioxide in aqueous solutions to inhibit corrosion or biological growth.^[3] In materials science and metallurgy, vacuum degassing of molten metals like steel or aluminum expels hydrogen and other volatiles, reducing inclusions and improving mechanical properties.^[4]^[5] Geologically, degassing encompasses the exsolution of volatiles from ascending magma in volcanoes, driving eruption styles and contributing to atmospheric gas fluxes, with excess degassing linked to intrusive magma formation and tectonic influences.^[6]^[7] These applications underscore degassing's role in causal processes from industrial quality control to planetary volatile cycling, though quantification challenges persist due to varying measurement techniques across scales.^[8]

Fundamentals

Definition and Physical Principles

Degassing is the process of removing dissolved or entrained gases from liquids, such as water, molten metals, or chemical solutions, to achieve desired purity, stability, or performance characteristics.^[2] This physical separation exploits differences in phase equilibrium and mass transfer dynamics between the gas and liquid phases.^[9] The primary physical principle underlying degassing is Henry's law, which states that, at constant temperature, the solubility of a gas in a liquid—expressed as the concentration of dissolved gas—is directly proportional to the partial pressure of that gas in the equilibrium vapor phase above the liquid.^[10] Mathematically, this is represented as C = k \cdot P, where C is the molar concentration of the dissolved gas, P is its partial pressure, and k is the Henry's law constant specific to the gas-liquid pair and temperature.^[11] To drive gas removal, external conditions disrupt this equilibrium: reducing partial pressure (e.g., via vacuum) decreases solubility, prompting dissolved gases to desorb and form bubbles; elevating temperature generally lowers k for most gases, further reducing solubility as thermal energy overcomes intermolecular forces binding gas molecules to the liquid; or introducing mechanical agitation enhances mass transfer by increasing the gas-liquid interfacial area and nucleation sites for bubble formation.^[9]^[12] Mass transfer in degassing follows Fick's laws of diffusion, where the flux of gas molecules from liquid to gas phase is proportional to the concentration gradient across the interface.^[13] In practice, methods like ultrasonic treatment leverage acoustic cavitation—rapid pressure oscillations generating microscopic vapor or gas cavities that collapse and release dissolved gases into larger bubbles for extraction—effectively supersaturating the liquid relative to ambient conditions.^[14] Membrane-based approaches rely on selective permeation driven by partial pressure differentials across a hydrophobic or selective barrier, often under vacuum, without direct liquid-gas mixing.^[15] These principles ensure efficient degassing while minimizing energy input and secondary contamination, with efficacy depending on factors like gas diffusivity, liquid viscosity, and surface tension.^[13]

Gas Solubility and Driving Forces

The solubility of gases in liquids is fundamentally governed by Henry's law, which states that at constant temperature, the concentration of a dissolved gas (C) is directly proportional to its partial pressure (P) above the liquid: C = k_H \cdot P, where k_H is the temperature-dependent Henry's law constant specific to the gas-liquid pair.^[16]^[17] This equilibrium relationship implies that gases dissolve exothermically in most liquids, with k_H decreasing (solubility increasing) under higher pressure but k_H increasing (solubility decreasing) with rising temperature, as heat disrupts the solute-solvent interactions favoring dissolution.^[16]^[18] In degassing processes, the primary driving force is the deviation from this equilibrium, creating supersaturation where the actual dissolved gas concentration exceeds the solubility limit under altered conditions, prompting diffusive mass transfer of gas molecules from the liquid phase to the vapor phase per Fick's first law of diffusion.^[19] Reducing the partial pressure—such as through vacuum application—directly lowers the equilibrium solubility, establishing a concentration gradient that accelerates gas exsolution, with the rate proportional to the pressure differential.^[20]^[16] Increasing temperature further enhances this by exponentially reducing solubility (e.g., oxygen solubility in water drops from 8.3 mg/L at 25°C to 6.4 mg/L at 40°C at 1 atm), providing an additional thermodynamic impetus for bubble nucleation and release once supersaturation thresholds are met.^[16]^[19] Other influences on solubility, such as salinity (which decreases gas solubility via the Setschenow effect) or chemical reactions forming less soluble species, modulate these driving forces but are secondary to pressure and temperature manipulations in physical degassing.^[21] Mass transfer kinetics are enhanced by factors like liquid agitation or reduced viscosity, which minimize diffusion path lengths and boundary layer resistance, though the underlying force remains the solubility disequilibrium.^[22] In practice, effective degassing requires balancing these forces to avoid incomplete removal or foaming, with quantitative models often incorporating Henry's constants calibrated for specific systems (e.g., CO₂ in water has k_H \approx 29.4 L·atm/mol at 25°C).^[21]^[20]

Historical Development

Early Techniques and Practices

Early degassing practices relied heavily on thermal methods, exploiting the inverse relationship between temperature and gas solubility as described by Henry's law. Heating liquids to or near boiling point facilitated the expulsion of dissolved gases such as oxygen, carbon dioxide, and hydrogen sulfide through increased volatility and bubble formation. In laboratory chemistry, prolonged boiling under atmospheric pressure—often for 15 to 30 minutes in loosely covered vessels—was a standard procedure to prepare degassed solutions, minimizing interference from bubbles in experiments like titration or spectroscopy.^[23] This approach was simple, requiring no specialized equipment beyond basic heating apparatus, and was documented in early 20th-century protocols for solvent preparation. In industrial water treatment and boiler systems, thermal deaeration emerged in the 19th century as boilers demanded oxygen-free feedwater to prevent corrosion. Early devices heated water to saturation temperatures, allowing gases to vent while steam stripping enhanced removal efficiency. By the 1920s, counter-current open feedwater heaters were introduced, combining heating with steam injection to systematically scrub dissolved gases, achieving oxygen levels below 0.005 mL/L in some designs.^[24] These systems marked a shift from ad hoc boiling to engineered processes, though limited by energy demands and incomplete gas removal for less soluble species like nitrogen. Mechanical agitation complemented thermal techniques, promoting gas release via surface renewal and nucleation sites. Stirring or refluxing liquids under heat increased interfacial area, accelerating diffusion-driven degassing in batch processes. Reflux methods, involving repeated vaporization and condensation, were particularly effective for volatile solvents in early analytical chemistry.^[25] In metallurgy, pre-vacuum degassing of molten alloys focused on indirect gas management through alloying or slagging rather than direct removal, as dissolved hydrogen and oxygen caused defects like porosity. The foundational concept of vacuum-assisted degassing for steel was proposed in 1940 by Soviet metallurgists A. M. Samarin and L. M. Novik, who advocated reduced pressure to lower the partial pressure of gases and induce evolution from the melt. Initial low-vacuum trials occurred in the 1940s, but scalable industrial implementation began in 1952 at the Enakievskii Metallurgical Plant in the USSR, using ladle evacuation to achieve hydrogen reductions from 10-15 ppm to under 2 ppm.^[4]^[26] These early efforts highlighted vacuum's superiority over thermal alone, though equipment limitations constrained adoption until post-war advancements.

Mid-20th Century Advances

In the field of steelmaking, vacuum degassing techniques advanced significantly during the 1950s to address inclusions and gas-related defects in molten steel. Batch vacuum degassing systems, such as stream degassing, were refined in the United States and Europe, with early installations enabling the treatment of steel under reduced pressure to remove hydrogen and other dissolved gases.^[27] By the late 1950s, the Dortmund-Hörder (DH) process emerged in Germany, involving the circulation of molten steel through a vacuum chamber via snorkel tubes, which improved efficiency over prior ladle methods and reduced processing times to under 30 minutes for heats up to 100 tons.^[28] The Ruhrstahl-Heraeus (RH) process, also developed in Germany around 1958, represented a key innovation by using argon gas to lift and recirculate steel between a ladle and a vacuum vessel, achieving hydrogen levels below 2 ppm and enhancing steel cleanliness for high-value applications like automotive and aerospace components.^[29]^[28] These vacuum methods supplanted earlier open-stream techniques, as they minimized oxidation and allowed precise control of alloying elements, with initial industrial trials demonstrating yield improvements of 1-2% in steel production.^[30] Ultrasonic degassing saw parallel progress, particularly for non-ferrous metals. Pioneering work in the 1940s explored sonic vibrations for removing gases from aluminum-magnesium alloys without direct contact, leveraging cavitation to nucleate and expel bubbles.^[31] By 1959, the Soviet-developed UZD-200 system enabled ultrasonic treatment of up to 250 kg melts in ladles, using frequencies around 20 kHz to achieve gas reductions of 50-90% in aluminum and magnesium alloys, paving the way for defect-free castings.^[32] These mid-century developments, driven by post-war industrial demands for purer metals, laid foundational principles for modern secondary metallurgy, emphasizing reduced pressure and acoustic energy to enhance gas removal kinetics over traditional thermal or chemical approaches.^[33]

Recent Innovations Since 2000

Since 2000, membrane degasification has gained prominence as an efficient gas-liquid separation technique, leveraging hydrophobic membranes to remove dissolved gases like CO2 and O2 from water and other liquids with reduced energy consumption compared to traditional packed towers.^[34] Advances include the development of antifouling hydrophobic membranes that minimize scaling and biofouling, enhancing longevity in desalination processes where non-condensable gases are stripped under vacuum or sweep gas conditions.^[35] By 2023, these systems demonstrated up to 99% removal efficiency for specific gases in industrial-scale applications, driven by improved module designs and material innovations like polypropylene and PVDF composites.^[34] Ultrasonic degassing has seen refinements in metallurgy, particularly for aluminum and magnesium alloys, where cavitation-induced bubble nucleation accelerates hydrogen removal and grain refinement.^[36] Post-2000 studies established optimal frequencies between 200-1000 kHz for maximal degassing at atmospheric pressure, with efficiency scaling nonlinearly with power input up to 1 kW, reducing porosity by 50-70% in castings.^[37] In aluminum composites, intermittent ultrasonic vibration schemes achieved relative densities exceeding 99.5% by 2024, outperforming continuous methods through controlled acoustic streaming that minimizes oxide entrapment.^[38] Vacuum degassing technologies advanced in steelmaking with the proliferation of Ruhrstahl-Heraeus (RH) and ladle vacuum systems, enabling treatment of melts up to 330 tons since 2000, which lowered hydrogen levels to below 1 ppm for ultralow-carbon steels.^[39] Claw vacuum pumps, such as MINK series integrated in extrusion lines by 2020, provided contactless operation with maintenance intervals extended to 20,000 hours, facilitating inline degassing of polymer melts at rates over 1000 kg/h while reducing dissolved volatiles by 90%.^[40] In sulfur recovery, the ICOn system, commercialized post-2010, employs catalytic conversion under vacuum to cut H2S emissions from 1000 ppm to under 10 ppm in elemental sulfur products.^[41] Hybrid innovations include the SNIF Sheer NEO rotary impeller system introduced around 2015 for aluminum foundries, which combines argon injection with electromagnetic stirring to boost inclusion removal by 40% over prior generations through redesigned nozzle geometries.^[42] For beverages, alternating high-vacuum cycles down to -800 mbar in coffee degassing units, refined by BMM Technology since the early 2000s, preserved flavor volatiles while extracting 95% of entrained CO2 within 24 hours post-roast.^[43] These developments emphasize scalability, with peer-reviewed validations confirming causal links between process parameters and gas removal kinetics via Henry's law deviations under dynamic conditions.^[37]

Physical Degassing Methods

Vacuum and Pressure Reduction

Vacuum and pressure reduction degassing operates on Henry's law, which states that the solubility of a gas in a liquid is directly proportional to the partial pressure of that gas above the liquid at constant temperature.^[9] Reducing the ambient pressure lowers the partial pressure, rendering dissolved gases supersaturated and promoting their diffusion to the liquid-gas interface for removal.^[44] This physical process avoids chemical additives, relying instead on mass transfer driven by concentration gradients at the boundary layer.^[4] In vacuum degassing, the material—typically a molten metal or liquid—is exposed to pressures as low as 0.1–1 mbar in sealed chambers equipped with pumps and sometimes stirring mechanisms to enhance gas evolution.^[45] For instance, in aluminum alloy processing, vacuum treatment reduces hydrogen content by nucleating and growing bubbles that rise and burst, expelling gas; efficiencies can exceed 90% under optimized conditions with rotational impellers.^[44] The rate-limiting step is often diffusion through the boundary layer, influenced by viscosity, temperature, and surface area, rather than bulk phase equilibrium.^[4] Pressure reduction without full vacuum, such as in staged decompression systems, applies milder reductions (e.g., from atmospheric to 100–500 mbar) in pipelines or vessels to release volatile hydrocarbons or dissolved air, common in petrochemical storage and transport.^[46] This method minimizes equipment complexity but achieves lower degassing rates compared to deep vacuum, as partial pressure gradients are smaller; it is frequently combined with monitoring for lower explosive limits to ensure safety during operations.^[47] In steel metallurgy, vacuum degassing treatments like ladle vacuum degassing (VD) or Ruhrstahl-Heraeus (RH) processes reduce hydrogen from ~10 ppm to below 2 ppm and remove inclusions by exposing ladles of 100–300 tons of melt to vacuum for 10–30 minutes.^[30] ^[48] These techniques improve ductility and fatigue resistance by mitigating hydrogen-induced cracking, with argon stirring often augmenting bubble formation and circulation. Limitations include energy-intensive pumping and potential for recontamination if vacuum seals fail, necessitating high-integrity systems.^[45]

Thermal Regulation

Thermal regulation in degassing leverages the inverse relationship between temperature and gas solubility in liquids or melts, as governed by Henry's law, which states that the solubility of a gas is proportional to its partial pressure above the liquid, and empirical observations like Winkler's law indicating reduced solubility with elevated temperatures for gases such as oxygen and carbon dioxide in water.^[49]^[50] By heating the medium to specific thresholds, dissolved gases become less soluble and migrate to the vapor phase for removal, often without additional mechanical or chemical aids. This method is particularly effective for non-reactive gases in aqueous solutions, where solubility of oxygen drops from 11.2 mg/L at 10°C to 0.12 mg/L at 100°C under atmospheric conditions.^[50] In industrial water treatment, thermal degassers operate by heating demineralized water to approximately 104°C in a controlled environment, typically using direct steam injection or indirect heating in tray, spray, or hybrid columns to strip gases like O₂ and CO₂, which are then vented overhead.^[50] Spray degassers, the most common variant, atomize water into a countercurrent steam flow, achieving residual oxygen levels below 7 ppb, while mixed spray-tray systems can reach under 3 ppb at the cost of higher complexity.^[50] Pressure is maintained slightly above atmospheric (e.g., 0.1-0.3 bar) to prevent excessive boiling, with automated controls including temperature sensors, pressure transmitters, level indicators, and flowmeters ensuring stable operation and preventing recontamination.^[50] This process meets standards like UNE-EN 12952-12:2004 for boiler feedwater, reducing oxygen to less than 0.02 ppm (20 ppb) to mitigate corrosion in high-pressure systems.^[50] In metallurgical applications, thermal regulation supports degassing by maintaining melt temperatures that optimize fluidity and gas diffusion rates, such as 1600–1650°C in vacuum degassing of steel to promote hydrogen and nitrogen exsolution without solidification.^[30] For aluminum alloys, however, elevated temperatures prolong required degassing times due to increased hydrogen absorption potential from atmospheric exposure, necessitating precise control to balance solubility reduction against re-entrainment risks during rotary or flux-assisted processes.^[51] Overall, thermal methods excel in scalability for large-volume water purification but require energy input for heating, with efficiencies enhanced by integration with vacuum or stripping to achieve sub-ppm gas residuals in corrosion-sensitive applications.^[49]

Ultrasonic Degassing

Ultrasonic degassing employs high-intensity ultrasound waves, typically in the frequency range of 20-40 kHz, to remove dissolved gases and entrained bubbles from liquids or molten materials through the generation of acoustic cavitation.^[52] The process induces the formation, growth, and violent implosion of cavitation bubbles, which create localized high-pressure and high-temperature conditions, microjets, and shock waves that facilitate the detachment and coalescence of gas bubbles for subsequent release at the liquid surface.^[53] In metallic melts, where natural gas bubbles are scarce, cavitation plays a critical role by nucleating sites for gas diffusion from the supersaturated solution into the bubbles, enabling efficient hydrogen removal without reliance on chemical additives or inert gas injection.^[32] The mechanism relies on the diffusion of dissolved gas molecules into cavitation voids, followed by bubble migration to the surface driven by buoyancy and acoustic forces; this contrasts with passive methods by accelerating mass transfer rates up to several orders of magnitude.^[54] Experimental studies on aluminum alloys demonstrate that ultrasonic treatment at amplitudes of 20-50 μm can reduce hydrogen content from 0.5-1.0 ml/100g Al to below 0.2 ml/100g Al within 2-5 minutes of exposure, significantly outperforming traditional rotary degassing in speed and uniformity.^[45] Optimal efficacy requires precise control of ultrasound power density (typically 10-100 W/cm²) and treatment duration to avoid excessive cavitation erosion on equipment or incomplete degassing due to bubble shielding in viscous media.^[55] In metallurgy, ultrasonic degassing is applied to aluminum and magnesium alloys during casting to minimize porosity, enhance mechanical properties such as tensile strength by 10-20%, and improve microstructural homogeneity by promoting grain refinement alongside gas removal.^[56] For instance, in aluminum melt processing, immersion probes or bath setups deliver ultrasound directly into the melt, reducing dissolved hydrogen—a primary cause of pinhole defects in castings—and enabling denser products suitable for aerospace and automotive components.^[36] Beyond metals, the technique degasses viscous liquids like polymers or oils and is used in glass refining to lower refining temperatures by 50-100°C, thereby cutting energy consumption.^[57] Advantages include rapid processing times (often under 5 minutes versus hours for vacuum methods), chemical-free operation that preserves melt purity, and scalability for continuous in-line systems, which minimize oxidation and dross formation compared to gas sparging.^[45] ^[55] Limitations encompass equipment wear from intense cavitation, challenges in treating large volumes due to ultrasound attenuation in depth (effective penetration limited to 10-20 cm in dense melts), and dependency on melt temperature and composition, where high viscosity can reduce bubble mobility and efficiency.^[32] Despite these, advancements in transducer design since the 2010s have expanded commercial viability, particularly in foundries seeking to optimize yield and quality.^[32]

Membrane Degasification

Membrane degasification employs hydrophobic microporous membranes to selectively remove dissolved gases from liquids, primarily through a pressure-driven diffusion process without direct gas-liquid contact beyond the membrane interface. The liquid flows along one side of the membrane, while a vacuum or inert sweep gas is applied to the opposite side, establishing a partial pressure gradient that compels gases like carbon dioxide (CO₂), oxygen (O₂), or hydrogen sulfide (H₂S) to desorb from the liquid, permeate through the membrane pores, and exit into the low-pressure zone. This method relies on Henry's law, where the solubility of a gas in a liquid is proportional to its partial pressure above the liquid; reducing the gas partial pressure on the permeate side shifts equilibrium toward degassing. Unlike traditional stripping towers, the membrane prevents liquid entrainment or flooding, enabling operation at near-atmospheric pressures and minimizing energy use for gas handling.^[34]^[35] Common configurations utilize hollow-fiber membrane contactors, where thousands of fibers provide a high surface-area-to-volume ratio—often exceeding 1,000 m²/m³—facilitating efficient mass transfer coefficients on the order of 10⁻⁵ to 10⁻⁴ m/s for CO₂ removal. Hydrophobic materials such as polypropylene (PP), polytetrafluoroethylene (PTFE), or polyvinylidene fluoride (PVDF) are selected for their low surface energy, ensuring pores (typically 0.01–0.5 µm) remain gas-filled and non-wetted by the aqueous phase under operational transmembrane pressures below the liquid entry pressure (e.g., <0.5 bar for PP). Vacuum degasification targets can achieve CO₂ levels below 2 mg/L or O₂ below 5 ppb in treated water, depending on residence time and vacuum level (e.g., 50–100 mbar), with sweep gas modes enhancing selectivity for specific gases. The process operates continuously at ambient temperatures, avoiding thermal degradation risks associated with heating-based methods.^[34]^[35]^[58] Advantages include a compact footprint (up to 80% smaller than packed columns), reduced energy consumption (typically 0.1–0.5 kWh/m³ treated), and absence of chemical additives, making it suitable for ultrapure water production in boiler feed or semiconductor rinsing. It outperforms conventional vacuum degassing by avoiding foaming or aerosol formation and provides higher removal efficiencies without excessive gas recirculation. However, membrane fouling from particulates or organics necessitates prefiltration, and module replacement intervals (3–10 years) can elevate capital costs, though operational savings often offset this. Emerging polymeric membranes with enhanced permeability, such as those incorporating polydimethylsiloxane composites, continue to improve flux rates for industrial scalability. Applications span water treatment for desalination pretreatment and corrosion prevention in power generation, where dissolved O₂ reduction mitigates pitting in carbon steel piping.^[34]^[59]^[35]

Chemical and Hybrid Degassing Methods

Inert Gas Sparging

Inert gas sparging involves the injection of non-reactive gases, such as nitrogen, argon, or helium, into a liquid medium through nozzles, lances, or porous plugs to facilitate the removal of dissolved reactive gases like oxygen or hydrogen via mass transfer across the bubble-liquid interface. The process creates a high surface area for diffusion, where dissolved gases partition into the rising inert gas bubbles and are expelled from the system, effectively reducing gas solubility without introducing chemical reactants.^[60] This method is particularly suited for oxygen-sensitive applications, as the inert gas displaces rather than chemically neutralizes the target gases, though it may leave trace amounts of the sparging gas dissolved in the liquid.^[61] In laboratory and chemical processing contexts, sparging is performed by bubbling the gas through sealed flasks or vessels at controlled flow rates, typically 500–1000 cc/min for 100-cc samples of water or organic solvents, achieving 95–98% removal of dissolved oxygen in 15–30 seconds.^[21] Argon is often preferred over nitrogen for its higher density, which enhances purging efficiency in preventing re-entry of atmospheric oxygen, and helium for its minimal solubility, allowing near-complete gas elimination except for itself.^[62] For volatile solvents like diethyl ether, cooling in an ice bath during sparging minimizes evaporative losses, with durations scaled to 1 minute per 5 mL of solvent for effective deoxygenation comparable to vacuum cycling but inferior to freeze-pump-thaw methods that evacuate all gases.^[61] In metallurgical applications, such as aluminum casting, inert gas sparging targets hydrogen removal from molten metal to prevent porosity defects, with argon or high-purity nitrogen (>99.99%) bubbled through the melt via immersed lances, promoting hydrogen diffusion into bubbles based on experimentally determined mass transfer coefficients at temperatures around 700°C.^[63] The technique outperforms static methods by enhancing circulation and gas-liquid contact but requires careful control to avoid excessive turbulence or metal oxidation if nitrogen reacts under certain conditions.^[64] Hybrid variants may incorporate trace halogens like chlorine for simultaneous fluxing of inclusions, though pure inert sparging prioritizes gas removal alone.^[65] Advantages include scalability for large volumes, as seen in water treatment where nitrogen sparging handles high throughput without equipment complexity, and rapid kinetics due to bubble-induced mixing.^[66] Limitations encompass potential incomplete removal if sparging gas solubility is high (e.g., nitrogen in water at 0.000014 mole fraction under standard conditions) and energy costs for gas compression, with efficiency further improvable via ultrasonics to boost mass transfer rates.^[21]^[67]

Reductant Addition

Reductant addition is a chemical degassing technique that employs reducing agents to react with dissolved gases, primarily oxygen, in liquids or melts, converting them into separable compounds such as oxides or sulfates.^[68] This method lowers gas solubility by direct chemical reduction rather than relying solely on physical processes like vacuum or heating. Common reductants include sodium sulfite for aqueous systems, sodium-benzophenone ketyl for organic solvents, and elements like aluminum, silicon, or calcium for molten metals.^[69]^[70]^[71] In water treatment, particularly for boiler feedwater, sodium sulfite (Na₂SO₃) serves as an oxygen scavenger through the reaction 2Na₂SO₃ + O₂ → 2Na₂SO₄, effectively reducing dissolved oxygen levels to below 0.005 ppm under optimal conditions.^[72] Catalyzed variants, incorporating cobalt or copper, accelerate the reaction rate, which is otherwise pH-dependent and inhibited by chelants or feedwater contaminants.^[69] This approach prevents corrosion in steam systems but introduces sulfate ions, necessitating monitoring to avoid scaling or environmental discharge issues.^[73] For organic solvent preparation in laboratory settings, sodium metal combined with benzophenone forms the ketyl radical (Ph₂C•O⁻Na⁺), which reduces oxygen to peroxide and indicates deoxygenation via a persistent deep blue-purple color upon completion.^[70] Solvents like tetrahydrofuran (THF) or diethyl ether are refluxed over this mixture, distilling the degassed product; the method simultaneously removes trace water by forming insoluble sodium hydroxide.^[74] It is favored for air-sensitive reactions but limited to non-reactive solvents, as ketyl radicals are incompatible with protic or halogenated compounds.^[75] In metallurgical processes, such as steelmaking or superalloy refining, aluminum and silicon act as reductants for deoxidation: 4Al + 3[O] → 2Al₂O₃ and 2Si + [O] → 2SiO (further oxidized to SiO₂), where [O] denotes dissolved oxygen.^[68] These form slag inclusions that can be floated or filtered, reducing oxygen content to support vacuum degassing hybrids. Calcium addition, often via wire injection, provides stronger reduction (Ca + [O] → CaO), enhancing removal of oxygen, nitrogen, and hydrogen in vacuum induction melting, with studies showing up to 90% oxygen reduction in IN713LC superalloy after 30 minutes of refining.^[71] However, excess reductants risk reoxidation or undesirable inclusions, requiring precise stoichiometry based on melt oxygen activity.^[76] This method integrates with ladle metallurgy but demands high-purity inputs to minimize impurities from reductant sources.

Freeze-Pump-Thaw Cycling

Freeze-pump-thaw cycling is a physical degassing technique employed in chemical laboratories to eliminate dissolved gases, such as oxygen or nitrogen, from solvents, solutions, or liquid reagents, thereby enabling air-free conditions for sensitive reactions.^[77] The method leverages the phase change of the liquid to immobilize it, allowing vacuum evacuation of gases from the headspace without significant solvent evaporation.^[78] It is most commonly applied on small scales, typically volumes under 50 mL, to minimize risks associated with thermal expansion.^[79] The procedure begins with transferring the liquid into a Schlenk flask or sealed tube, filling no more than 50% of the vessel volume to accommodate expansion, and closing the stopcock.^[79] The flask is then immersed in a cryogenic bath, such as liquid nitrogen at -196°C or a dry ice-acetone slurry at approximately -78°C, to rapidly freeze the contents solid.^[78] Once frozen, the stopcock is opened to a high-vacuum line (typically <10^{-3} torr), and the system is evacuated for 2-3 minutes to remove gases desorbed from the solid-liquid interface and headspace.^[78] The vacuum is then closed, and the sample is allowed to thaw gradually at room temperature or under controlled warming, promoting the release of trapped gases into the headspace for subsequent evacuation.^[79] This cycle is repeated 3-5 times, with thawing performed from the top downward to avoid pressure buildup and potential vessel fracture.^[61] Effectiveness stems from the repeated disruption of gas solubility: freezing expels dissolved gases as bubbles that migrate to the surface, while vacuum removal prevents re-dissolution during thawing.^[80] Studies and protocols indicate it achieves near-complete degassing for non-volatile solvents, outperforming single-cycle vacuum degassing by reducing oxygen levels to below 1 ppm after multiple iterations.^[78] However, efficacy diminishes for highly volatile or low-boiling-point liquids, where partial evaporation can occur despite sealing.^[61] In practice, the technique integrates with Schlenk line setups for inert atmosphere handling, making it suitable for organometallic synthesis or polymerization reactions intolerant to oxidative impurities.^[77] Advantages include minimal solvent loss compared to gas sparging—ideal for costly or hazardous reagents—and no introduction of foreign gases, ensuring purity.^[78] Drawbacks encompass time intensity (each cycle taking 10-20 minutes), equipment requirements like vacuum manifolds, and safety hazards from implosions if vessels are overfilled or thawed unevenly.^[79] For larger scales, alternatives like ultrasonic or membrane degassing are preferred due to scalability limitations.^[61]

Industrial Applications

Metallurgy and Steelmaking

In steelmaking, degassing is essential to remove dissolved gases such as hydrogen, nitrogen, and oxygen from molten steel, which can otherwise cause defects like flaking, embrittlement, and inclusions that compromise structural integrity and mechanical properties.^[4] Hydrogen, primarily introduced from moisture in scrap or lime, leads to delayed cracking upon solidification, while nitrogen from ferroalloys or air entrainment promotes brittleness; oxygen contributes to non-metallic inclusions.^[81] These processes occur during secondary metallurgy in ladles after primary melting in electric arc furnaces or converters, enabling production of high-quality steels for applications requiring uniformity and cleanliness.^[28] Vacuum degassing, a core technique, involves exposing the molten steel to reduced pressures (typically 0.5–10 mbar) in a sealed chamber, decreasing gas solubility and promoting diffusion across the gas-metal interface.^[28] Common variants include tank degassing (VD), where steel in a ladle is treated statically; circulation types like Ruhrstahl-Heraeus (RH), processing up to 110 tons in 20 minutes via dual snorkels for enhanced surface renewal; and Dortmund-Hörder (DH), using a single snorkel for 10–15% circulation per cycle.^[28] Hydrogen levels are routinely lowered to below 2 ppm (as low as 1.5 ppm), while nitrogen removal is less efficient at under 20%, often supplemented by argon stirring to increase mass transfer.^[28]^[81] Benefits include improved desulfurization (up to 80% in some systems), alloy homogeneity, and reduced inclusions, with treatment times of 20–30 minutes; the process originated industrially in the 1950s following early proposals in the 1940s.^[28]^[4] For stainless and alloy steels, vacuum oxygen decarburization (VOD) integrates oxygen lancing under vacuum (100–250 mm Hg) to simultaneously decarburize to below 0.005% carbon and degas, protecting elements like chromium from oxidation.^[28] Argon oxygen decarburization (AOD), conducted in a converter, employs controlled argon-oxygen mixtures (argon diluting oxygen to minimize chromium loss) blown through submerged tuyeres, generating CO bubbles that stir the bath and facilitate hydrogen and nitrogen expulsion via inert gas dilution and flotation.^[82] The process reduces carbon from 1.5–2.5% to under 0.05% in 20–35 minutes, with gas flows of 1–3 Nm³/min per ton, enabling sulfur levels below 0.005% and nitrogen control in grades like 304 stainless (solubility around 0.23%).^[82] AOD's steps—decarburization, reduction with ferrosilicon for chromium recovery, and desulfurization—enhance metallic yields and raw material flexibility, making it dominant for producing low-carbon stainless steels since its development in the 1960s.^[82] Inert gas sparging, often argon bubbling in ladles, complements vacuum methods by inducing circulation to accelerate hydrogen and nitrogen removal without vacuum equipment, reducing oxygen activity and inclusions through flotation.^[4] These techniques collectively enable steel with exceptional ductility and fatigue resistance, critical for aerospace, automotive, and structural components, though nitrogen control remains challenging due to its lower diffusivity compared to hydrogen.^[81]^[28]

Oil and Petrochemical Processing

In oil production, degassing stabilizes crude by extracting dissolved gases and hydrogen sulfide at the wellhead or stabilization units, mitigating corrosion in pipelines and storage, while enhancing transport safety and product quality.^[83] Associated natural gas liquids (NGLs), which emerge as byproducts during extraction, undergo degassing to separate lighter hydrocarbons and prevent pipeline blockages from gas accumulation at high points. Self-acting float-controlled bleeding valves, constructed from corrosion-resistant stainless steel, facilitate this by continuously discharging gases without external power, operating effectively up to 130°C and with fluid densities as low as 640 kg/m³.^[84] In refinery operations, degassing targets volatile organic compounds and entrained vapors from process streams to avoid downstream equipment damage and ensure compliance with safety thresholds.^[85] Petrochemical processing employs degassing primarily during equipment shutdowns and turnarounds to eliminate hazardous residues like hydrocarbons, hydrogen sulfide, mercaptans, and pyrophoric iron sulfides from reactors, vessels, and piping before maintenance. Chemical methods accelerate this by circulating or injecting scavengers—such as hydrocarbon encapsulators (e.g., Purge C) or H2S neutralizers (e.g., Sourguard)—often augmented with steam to elevate system temperatures to approximately 90°C, promoting gas release and emulsification while reducing lower explosive limit (LEL) concentrations below ignition thresholds.^[47]^[86] These interventions, sometimes preceded by solvent decontamination to clear heavy deposits, minimize worker exposure to flammables and toxics, shorten downtime to as little as 12 hours, and curb environmental releases of volatile emissions.^[87] Vacuum-assisted or inert gas techniques may supplement chemical approaches in high-precision applications, though steam-chemical hybrids predominate for their efficacy against persistent sulfides.^[88]

Water Treatment and Purification

Degassing in water treatment removes dissolved gases such as oxygen, carbon dioxide, and hydrogen sulfide from water supplies, mitigating corrosion in piping and equipment, reducing acidity to stabilize pH, and eliminating odors or tastes that affect palatability.^[89]^[90] In industrial and municipal contexts, untreated dissolved oxygen levels exceeding 0.1 mg/L can accelerate pitting corrosion in metal surfaces, while excess carbon dioxide lowers pH below 7, promoting further degradation and scaling when combined with hardness ions.^[91]^[92] These processes enhance water quality for downstream uses, including boiler operations and potable distribution, by targeting gas solubilities governed by Henry's law, where lower partial pressures or temperatures facilitate stripping.^[93] A primary application occurs in boiler feedwater preparation, where deaeration targets oxygen removal to levels below 7 parts per billion, preventing oxidative corrosion in high-pressure steam systems that operate above 100°C.^[94] Pressure deaerators, often operating at 5-15 psig and 105-120°C, scrub gases via steam contact, simultaneously heating feedwater to minimize thermal shock upon boiler entry and removing carbon dioxide to curb acidic condensate formation.^[91]^[95] This is essential in power generation and manufacturing, where untreated feedwater corrosion costs industries billions annually in maintenance and downtime, as evidenced by U.S. Department of Energy assessments of steam system efficiencies.^[94] In municipal drinking water treatment, decarbonation addresses carbon dioxide ingress from sources like groundwater, which can elevate levels to 50-100 mg/L, necessitating post-ion-exchange degassing to neutralize acidity and reduce chemical dosing for pH adjustment.^[96]^[92] Towers or packed columns strip CO2 via countercurrent air or vacuum flow, achieving reductions over 90% and improving chlorine stability while curbing pipe leaching of metals like lead.^[97] Hydrogen sulfide degassing similarly targets odor thresholds below 0.05 mg/L in well waters, using similar stripping to prevent bacterial growth and consumer complaints in distribution networks.^[93] Industrial purification for pharmaceuticals, semiconductors, and food processing demands ultra-low gas content, with membrane or vacuum systems reducing oxygen to sub-ppb traces for corrosion-free ultrapure water loops.^[98] These applications, integrated after softening or reverse osmosis, ensure compliance with standards like those from the International Purity for Ultrapure Water, minimizing defects in sensitive processes such as microchip fabrication where gas-induced bubbles compromise yields.^[3]

Food and Beverage Processing

Degassing in food and beverage processing removes dissolved gases, particularly oxygen (O₂) and carbon dioxide (CO₂), from liquids to mitigate oxidation, preserve flavor profiles, and prolong shelf life. This process prevents enzymatic browning, vitamin degradation, and microbial proliferation in products such as juices, milk, and water bases. Vacuum degassing predominates, applying reduced pressure to liberate gases, often combined with agitation or stripping agents like CO₂ for enhanced efficiency.^[99]^[100]^[101] In soft drinks and mineral water production, degassing targets oxygen removal from source water via vacuum chambers with continuous pumping, averting flavor oxidation and maintaining beverage clarity. Single-stage spray degassing suffices for oxygen levels adequate in this sector, typically integrating flowmeters and pressure sensors for process control.^[99]^[102] Breweries employ degassing for process water used in kieselguhr filtration, pipe rinsing, and high-gravity beer blending, achieving residual oxygen below 0.02 ppm to minimize beer flavor alteration and oxygen ingress. Multi-stage spray or column methods, sometimes with CO₂ stripping, outperform single-stage approaches required for beer compared to soft drinks. Membrane degassing via hollow fibers under vacuum also attains <0.02 ppm for smaller-scale operations.^[102]^[100] For juices, purees, and milk, vacuum degassers operate at 60–65°C and 0.08 MPa vacuum, eliminating suspended gases to curb foaming during filling and corrosion in packaging, with capacities reaching 15,000 L/h. These systems incorporate aroma recovery condensers to retain volatile flavors in fruit-based products like orange juice or tomato sauce, supporting densities from 0.5–2.5 g/cm³ and particle sizes up to 1000 µm.^[101]^[103] In wine and dealcoholized beer production, two-stage vacuum column degassing reduces oxygen to <10 ppb without heating or stripping gases, integrating with pasteurization to safeguard product integrity against oxidative off-flavors.^[100]

Unintended Degassing and Risks

Unintended degassing in industrial processes occurs when dissolved or entrained gases are suddenly released due to changes in pressure, temperature, or chemical reactions, often resulting in pressure surges, equipment ruptures, or hazardous releases. These incidents can arise from inadequate process controls, material incompatibilities, or procedural errors, leading to explosions, toxic exposures, or fires. Such events underscore the risks in handling reactive substances or supersaturated solutions where gas evolution is not anticipated or mitigated.^[104] On May 30, 2007, at a special waste treatment center in France, a road tanker containing incompatible wastes—30% hydrogen peroxide mixed with 5% acid resins from a paper mill transfer error on May 29—underwent exothermic decomposition, generating gases that caused a sudden pressure surge. The manhole lid ruptured, propelling the tanker 15 meters and ejecting waste material; cooling water was applied for 30 minutes to control the reaction. One employee sustained partial foot burns, prompting evacuation of operations staff, while administrative personnel remained in offices; the incident highlighted failures in waste acceptance protocols, including lack of temperature monitoring and venting.^[105] In a 1993 incident at a Dutch caprolactam production plant, the degassing line connected to filter B of a gas/slurry loop reactor (Hyam process) ruptured on July 23 due to an internal detonation, likely from methane accumulation or ignition during routine degassing operations. The explosion damaged the line, but specific injury or further release details were not publicly detailed in investigations; analysis attributed it to uncontrolled gas buildup in the slurry filtration and degassing system, emphasizing the need for detonation arrestors and inerting in polymer reactor degassing.^[104]^[106] Degassing-related toxic releases have also occurred during handling of corrosive chemicals; for instance, a test on a damaged phosphorus trichloride (PCl3) iso-container led to a large cloud of PCl3 and hydrogen chloride gas, necessitating emergency response and highlighting risks of incomplete neutralization or pressure relief failures in container degassing procedures. These cases illustrate how unintended degassing amplifies hazards in chemical and waste processing, where empirical monitoring of gas solubility and reaction kinetics is critical to prevent cascading failures.^[107]

Environmental Releases and Impacts

Unintended degassing in petrochemical and oil processing often results in fugitive emissions of volatile organic compounds (VOCs), methane, and hydrogen sulfide (H2S) during tank or vessel maintenance when vapor control systems fail or are bypassed. Traditional atmospheric venting methods, used historically for tanker degassing, release these hydrocarbon vapors directly into the air, contributing to localized air pollution.^[108] ^[46] In regions like the Netherlands, emissions from degassing inland tank vessels total approximately 1.79 kilotons of VOCs annually, equivalent to 1.2% of national VOC emissions, with potential higher contributions from toxic components.^[109] In the oil and gas sector, unintended degassing-related venting and leaks from storage tanks and equipment release methane, a greenhouse gas with a global warming potential 28-36 times that of CO2 over a 100-year period. The U.S. Environmental Protection Agency identifies equipment venting—often tied to degassing operations—as a key source of such emissions, alongside unintentional leaks, with global oil and gas methane outputs estimated at 82.5 million metric tons per year.^[110] ^[111] These releases amplify atmospheric methane concentrations, accelerating short-term climate forcing and representing lost commercial value exceeding $1 billion annually in the U.S. alone from major operations.^[112] Environmental impacts include enhanced tropospheric ozone formation from VOCs via photochemical reactions, leading to smog and respiratory health risks in downwind areas; methane's contribution to radiative forcing, exacerbating global warming; and H2S's role in acid deposition, which harms vegetation and aquatic ecosystems. In metallurgy, such as steelmaking, unintended off-gas releases from degassing—containing hydrogen, nitrogen, and oxygen—can occur if emission controls are inadequate, though vacuum processes generally reduce overall chemical emissions compared to alternatives.^[113] Regulatory frameworks, like those from the Texas Commission on Environmental Quality, mandate vapor recovery or combustion to mitigate these risks during degassing.^[114]

Health and Safety Considerations

Degassing operations, particularly in industrial settings like oil processing and metallurgy, expose workers to toxic gases such as hydrogen sulfide (H2S) and volatile organic compounds (VOCs), which can lead to acute respiratory distress, neurological effects, or fatality at concentrations above 500 ppm for H2S.^[115] ^[116] In petrochemical vessel degassing, incomplete removal of flammable vapors risks explosions if lower explosive limit (LEL) levels are not monitored and scavenged, as evidenced by incidents involving hydrocarbon releases during tank openings.^[47] ^[117] In metallurgical vacuum degassing of steel, primary hazards include burns from molten metal at temperatures exceeding 1,500°C, inhalation of dust-laden off-gases containing carbon monoxide (CO) and hydrogen (H2), and potential system failures leading to sudden pressure changes or leaks that could ignite flammable byproducts. Noise levels often surpass 85 dB, contributing to hearing loss without proper protection, while hot, dust-laden off-gases require cooling and post-combustion to mitigate release risks.^[118] Water treatment degassing via membrane methods reduces chemical exposure compared to traditional vacuum techniques but still necessitates ventilation to prevent asphyxiation from displaced oxygen.^[119] Mitigation strategies, as outlined in OSHA and NIOSH guidelines, emphasize continuous gas monitoring, personal protective equipment (PPE) including respirators and flame-retardant clothing, and adherence to confined space entry protocols under 29 CFR 1910.146 to address risks during manual gauging or vessel access.^[115] ^[120] Operator training on emergency response, such as immediate medical evacuation for H2S exposure, and routing vapors to thermal oxidizers during tank degassing have reduced incidents, though underreporting persists in high-risk sectors.^[121] In food and beverage processing, inert gas degassing poses lower toxicity risks but requires safeguards against oxygen displacement leading to hypoxic environments.^[122]

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Some forms of degasification are required for the production of cosmetics, medicines, and chemicals. However, water is by far the most common application needed ...
[99]
Degasing in soft drinks & mineral water production - KROHNE Group
Degassing removes dissolved gases, especially oxygen, from water used in soft drinks to prevent oxidation and damage to taste. Vacuum and pumping are used.
[100]
Degassing - corosys beverage technology GmbH & Co. KG
Reducing operating pressure (vacuum) · Increasing water temperature · Reducing partial pressure by using a stripping gas, preferably in countercurrent flow ...
[101]
Vacuum Degasser for Beverage and Milk - IBC MACHINE
Jul 27, 2021 · This vacuum degasser is mainly used for removing air and oxygen in the beverage to extend the shelf life and enhance the quality of the milk ...
[102]
Water degassing in the brewery
Single-stage spray degassing is often sufficient for the oxygen values required in the soft drinks industry and is therefore widely used in this field.
[103]
Vacuum degasser for juices and purees - Making.com
Enhance the quality of your liquid products with efficient degassing and flavor recovery, crucial for maintaining taste and consistency in juices, purees, and ...
[104]
Detonation of degassing line at gas/slurry loop-reactor - ScienceDirect
On Friday 23 July 1993, the degassing line of filter B of the hyam reactor was ruptured due to an internal explosion. During the investigation that followed ...
[105]
Sudden degassing of a road tanker in a special waste treatment centre
At an industrial waste treatment centre, a pressure surge due to the decomposition of wastes contained inside a tanker truck accepted into the site broke ...Missing: unintended | Show results with:unintended
[106]
[PDF] Methane (gas) - processing
1993. Summary. Degassing line of a filter of a hyam reactor. At a caprolactam plant was ruptured due to. An explosion (detonation). Country. NL. Activity.
[107]
Toxic release when degassing a container of PCl3 - ARIA
A large cloud of phosphorus trichloride (PCl3) and hydrogen chloride was released during a degassing test conducted on a PCl3 iso-container damaged during an ...Missing: processing | Show results with:processing
[108]
The evolution of tanker degassing: from venting to oxidation systems
Aug 16, 2025 · For decades, tanker degassing operations relied on simple atmospheric venting methods that released harmful vapours directly into the air you ...
[109]
Update estimate emissions degassing inland tank vessels - CE Delft
Results show that emissions amount to 1.79 Kton, or 1.2% of Dutch national VOC emissions. The contribution might be larger for specific toxic components, such ...Missing: petrochemical | Show results with:petrochemical
[110]
Primary Sources of Methane Emissions | US EPA
Aug 18, 2025 · As gas moves through the system, emissions occur through intentional venting and unintentional leaks. Venting can occur through equipment ...
[111]
The Oil and Gas Industry's Methane Problem in Four Charts
Aug 10, 2022 · The oil and gas industry was responsible for 82.5 million metric tons of methane emissions ... The remainder came from unintentional leakages, ...
[112]
Methane emissions from major U.S. oil and gas operations higher ...
Mar 13, 2024 · These emissions, which result from both intentional vents and unintentional leaks, amount to $1 billion in lost commercial value for energy ...
[113]
Degassing Process in Steelmaking: Enhancing Quality & Purity
May 22, 2025 · The degassing process removes dissolved gases from molten steel, improving quality, mechanical properties, and ensuring defect-free steel ...
[114]
Controlling VOC Emissions from Degassing Storage Tanks ...
Apr 25, 2025 · Control requirements reduce VOC emissions from the degassing of storage tanks, transport vessels, and marine vessels. Apply to degassing during, ...Missing: petrochemical | Show results with:petrochemical
[115]
[PDF] OSHA NIOSH Hazard Alert - Health and Safety Risks for Workers ...
Exposure assessment studies conducted by NIOSH and OSHA have identified worker health and safety risks that occur when workers open thief hatches and manually ...
[116]
Characterizing multifaceted environmental risks of oil and gas well ...
Jan 1, 2025 · Human exposure to H2S concentrations exceeding 500 ppm causes immediate death, while low level exposure can cause a variety of symptoms, ...Missing: degassing | Show results with:degassing
[117]
Chemical Hazards of Vessel Degassing: A Comprehensive Guide
Aug 12, 2024 · Vessel degassing is the process of safely venting or extracting gases from storage tanks, pipelines, or other enclosed spaces. These gases can ...
[118]
[PDF] Acciaio Off-gas preparation for vacuum pumps Memorie
Vacuum steel degassing plants generate off-gases that are hot, dangerous and dust laden. Therefore they must be cooled down, post-combusted or conveyed in a ...
[119]
Increasing occupational safety through softening and membrane ...
Both softening and membrane degassing are processes that do not involve the use of chemicals. This also means that no ingredients are added to the water that ...
[120]
Oil and Gas Well Drilling, Servicing and Storage - Storage Tanks
OSHA's permit-required confined spaces standard (29 CFR 1910.146) must be followed whenever employees enter permit spaces. In addition, petroleum and ...
[121]
5 Safety Tips for Tank and Vessel Degassing | Envent Corporation
May 17, 2019 · During the degassing phase, tank vapors should be routed to a thermal oxidizer for processing. The thermal oxidizer will work to thermally crack ...
[122]
What safety precautions should be taken when using a degassing ...
May 29, 2025 · Using a degassing machine safely requires a combination of pre - operation checks, operator training, personal protective equipment, ventilation ...Missing: considerations | Show results with:considerations