What is the sheath material of your elements? I'm not an expert, but check into Incolloy perhaps? There may also be an issue with watt density.

Flashlight,

Your question is too vague. Provide some additional details such as generator capacity, use, but most importantly, the characteristics of the feedwater, e.g., chemical analysis and pH.

Bad feedwater could be eating up your equipment.

Have you considered zinc oxide or zinc acetate for your water chemistry. Zinc provides a nice sacrificial anode.

Maybe these guys can help you ... http://www.technopieux.com/index.php?page=techno-protection&hl=usa

They manufacture a forced-current protection system that forces electricity into metal devices, rather than use a sacrificial anode.

One of their systems currently protects the rebar of the World's biggest mosque in Morocco.

Either way, good luck!

DZ

Dear Sir: Does your Steam Generator have A Water Holding Tank? If So, Something Like A House Hot Water Tank, it could be Mounted Vertically & Have ONE or TWO ANODE RODS to remove IRON, Various Minerals That Would Increase Corrosion. Also You should have A CONDENSATION RETURN to this Water Holding Tank. Install a Filter in this return line, choosing the better SILVER FILTER, many more PARTICLES Causing the Corrosion Would Be Caught. Your Retired Power Plant Technician Trouble Shooter.

Any boiler that produces steam needs makup water treatment. Removing minerals and dissolved oxygen makes a major difference to boiler life. Sacraficial anodes and current protection only work when properly applied, and its not always as easy as it sounds. Pay a lot of attention to tests of your water first, and your heating elemement materials second.

Please use distilled water for your make-up in your steam generator.If you can return all your condensate, and have a tight system [not exposed to atmosphere],better. Otherwise tds is your culprit.

We don't know yet all the details of your steam system.

If it is a closed system, returning all condensate to the feed water reservoir, this is better. If the steam is expended as "live steam," or if there are leaks, this must be made up with fresh water. Distilling it may not be practical, so you may need to control the TDS (total dissolved solids) and the dissolved oxygen. Preheating the water drives off much of the oxygen; preheating tanks are also described as deaerators. Oxygen in the feed water produces corrosion pits in the tubes and/or heating elements, weakening them. Minerals precipitate on these same surfaces; the build-up of scale reduces the heat transfer. These conditions can also be treated chemically, with dosage depending on what an anaylsis of the boiler water shows.

Not a precise answer ; But I will suggest to concentrate on (a) water chemistry and (b) Material selection in future units

With regards