Category: Press Release

Scale and rust can build up over time in heat exchangers, chillers, cooling towers, and other circulating water systems—especially those that are not properly treated. Failing to prevent scale buildup leads to the need to either chemically or mechanically remove scale to maximize designed heat transfer efficiency, good pipe flow, and equipment integrity. One great way to do this is with EcoClean^® Biodegradable Scale and Rust Remover Powered by Nano-VpCI^™, a USDA Certified Biobased Product available from Cortec^® Corporation.

Why Remove Scale and Rust?

Scale buildup does two things. It insulates metal surfaces and clogs piping. This makes equipment work harder to transfer the desired amount of heat and pump the water through the system. In extreme situations this can lead to equipment downtime and failures. Rust has similar effects and also represents the loss of metal and the potential for leakage and shortened service life. The situation only gets worse the longer it is neglected. Periodic scale removal every one to three years, or whenever an unexpected drop in heat exchange temperature is noticed, is a best practice for keeping scale and rust buildup under control and avoiding the extra costs, repairs, and other headaches associated with 10, 15, or even 20 years of accumulation.

Multi-Metal, Biobased Scale Remover from Cortec^®

EcoClean^® Biodegradable Scale and Rust Remover Powered by Nano-VpCI^™ is a heavy-duty product that works quickly to dissolve heavy scale and oxides (rust/corrosion) off metals. Unlike some products that cannot be used on aluminum or stainless steel, it is safe to use on multiple metal types, making it flexible for many different materials encountered in water treatment applications:

• Carbon steel
• Stainless steel
• Copper
• Aluminum

EcoClean^® Biodegradable Scale and Rust Remover Powered by Nano-VpCI™ contains 100% USDA certified biobased content and is easily biodegradable, giving it a positive environmental profile on two counts.

How to Remove Scale with EcoClean^®

EcoClean^® Biodegradable Scale and Rust Remover should be used regularly to avoid more serious problems in heat exchange systems. The product comes in three forms: liquid, powder, and water-soluble pouch. The liquid version should be added to water at a 1:2 ratio and, if desired, can be sprayed inside open tube bundles. The powder version can be added to water at 7% by weight and used in the same manner as the liquid. The pouch version is convenient for circulating systems and can simply be tossed in the water and allowed to dissolve and circulate for a few minutes without dismantling the equipment. Leaving the product to sit for 20-30 minutes thereafter is a good way to give the product time to work and dissolve existing rust and corrosion before flushing out the system. Use of EcoClean^® Biodegradable Scale and Rust Remover should be followed by neutralization with an alkaline cleaner such as those in the VpCI^®-41x Series, which also provide flash rust protection.

Don’t Wait—Now Is the Time to Maintain

Waiting to remove scale and rust only makes the problem worse. Routine maintenance with EcoClean^® Biodegradable Scale and Rust Remover is an excellent option for those who want to improve flow and heat transfer efficiency while using a biobased product and avoiding more serious system problems down the road. Contact Cortec^® to learn more about using this biobased scale and rust remover in your heat exchanger, chiller, or cooling tower!

Keywords: heat exchanger efficiency, how to descale heat exchanger, scale removal, descaler, remove corrosion from piping, remove scale, biobased scale remover, heat exchanger cleaning, Cortec, improve water flow 

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Finding the best paint for metal involves much more than picking a favorite color. In addition to good adhesion and rust prevention, a metal coating must be equipped to meet force-dry, high slip, or high temp requirements in certain applications. To address these needs, Cortec^® offers two specialty versions of EcoShield^® VpCI^®-386, a high-performing water- based anticorrosion coating for industrial applications.

Two Anticorrosion Paints—Three Special Features

EcoShield® 386 FD is a water-based acrylic one coat system that can be applied direct-to-metal (DTM) for protection in harsh, outdoor, unsheltered applications. It was specifically designed for fast-paced, force-dry applications, common in manufacturing environments. In addition to outstanding corrosion protection at 1.5-3.0 mils (37.5-75 µm) DFT (dry film thickness), EcoShield^® 386 FD force-dries in just 5-10 minutes at 150 °F (65 °C) and has good hot hardness. EcoShield® VpCI®-386 HT Slip Coating is another direct-to-metal water-based topcoat that offers excellent corrosion protection at 1.5-2.0 mils (37.5-50.0 µm) DFT. It is heat resistant up to 500 °F (260 °C) or more (depending on color) and improves surface slip. The coating is thixotropic and resists sagging and running during application. Both EcoShield^® 386 FD and EcoShield^® VpCI^®-386 HT Slip Coating are UV resistant and low VOC.

Where Are Force-Dry, Extra Slip, High Temp Coatings Needed?

While it would be difficult to list all the industrial applications where force-dry, extra slip, or high temp coatings could be used, the following examples are excellent springboards for exploring options.

Force-Dry Applications:

Fast-paced manufacturing applications are the number one candidate for EcoShield^® 386 FD. Many spray or dip lines move so quickly that the parts pile up at the end of the line. This is bad news if parts are hot and sticky—they could easily adhere to each other and potentially damage the coating when components are pulled apart. EcoShield^® 386 FD, which is designed for force-dry applications and has good hot hardness, will reduce the risk of parts sticking together. This feature is a potentially huge advantage in countless manufacturing applications where pipes, hooks, castings, and a variety of other equipment components are made.

Extra Slip Applications:

Electrical conduits are a prime example of where EcoShield^® VpCI^®-386 HT Slip Coating is beneficial. A protective ID (inner diameter) coating can be critical for new piping stored outdoors or shipped through harsh, corrosive conditions. However, when it comes time to install the conduits, electrical wires must be able to slide easily through the tubing. EcoShield^® VpCI^®-386 HT Slip Coating makes this possible while also inhibiting corrosion. The same benefits would apply to other metal surfaces, parts, or equipment in need of a protective coating that is slippery.

High Temp Applications:

In addition to needing extra slip, electrical conduits are a great illustration (although by no means the only example) of a high temp application. These pipes start out as flat pieces of metal that are rolled into tubes, welded, and internally painted before the welding heat can cool down. EcoShield^® VpCI^®-386 HT Slip Coating was designed to withstand this extra heat during coating application and similar high heat curing processes. It can also be used on equipment that may reach temperatures up to 500 °F (260 °C) during operation.

The main purpose of Cortec^® Coatings is to protect metals from corrosion. However, when special requirements such as force-drying, extra slip, or high temps enter the equation, Cortec^® is ready to make the solution fit the need. Contact Cortec^® to find out if these two specialty coatings are the right paints for your metal!

Keywords: paint for metal, corrosion inhibitors, rust prevention, anticorrosion coating, Cortec, metal coating, metal corrosion, water-based coating, problem with painted parts sticking together, high temp coating

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Corrosion comes in many different forms with many different solutions, which is why it is important to be aware of the multiple metal types in need of protection. Someone who does not take this into account may do more harm than good by trying to inhibit corrosion with the wrong chemistry. Cortec^® suggests looking at three key factors to understand some of the corrosion risks and abundant solutions when yellow metals are in the picture.

Key 1: Know What Is Inside Your Application

Whenever a manufacturer, project owner, or other individual seeks a corrosion solution, it is imperative to ask what types of metals are in the system. This is because yellow metals need different corrosion inhibitors than ferrous metals (e.g., steel), and because some ferrous rust inhibitors are actually aggressive to yellow metals. A small mistake of not realizing that a copper sensor or other yellow metal is present inside a tank treated with corrosion inhibitors aggressive to yellow metals can cause serious problems for the end user and the consultant who prescribed the product, leaving everyone worse off than if they had done nothing. Some common examples of equipment containing yellow metals are electrical cabinets and heat exchangers. Countless others exist throughout the industrial world. It is therefore part of the user’s due diligence to verify whether any yellow metals are present before applying treatment.

Key 2: Know What Is Surrounding Your Application

It is also important to know what is on the outside of the application. In other words, how corrosive is the surrounding environment? Yellow metals like brass and copper are typically more resistant to corrosion than ferrous metals and are often used for this reason. However, extra protection may be needed for harsh environments such as those experienced by new copper wires and tubing being shipped overseas, electrical panels and control boxes installed at paper mills or wastewater treatment plants, and copper heat exchanger tubing in refineries with high sulfuric gases. In short, more corrosives raise the risk of corrosion and warrant additional protection.

Key 3: Know What the Product Is Like

The next step is to match the corrosion inhibiting product to the application. First and foremost, verify the product is not aggressive to yellow metals. A close second priority is to find a product that actively protects yellow metals. Fortunately, a wealth of options exists, as most Cortec^® VpCI^® materials include multi metal protection unless otherwise noted. Third, it is important to match the product characteristics to the type of application. Some great examples are as follows:

• CorShield^® VpCI^®-146 Paper for protection of copper parts and wire during shipment
• VpCI^®-105 and VpCI^®-111 Emitters for protection of electrical cabinets (with built-in installation date stickers)
• ElectriCorr™ VpCI^®-239 for cleaning and protection of electrical contacts in ventilated cabinets
• Cooling Loop Gator^® for cooling tower layup
• VpCI^®-308 Pouch for protection of large voids up to 35.3 ft³ (1 m³) containing yellow metal components
• VpCI^®-126 Bags and BioPad^® for easy packaging and shipment of yellow metal goods
• Corrosorber^® cups for absorbing hydrogen sulfides in oil and gas or wastewater environments

Get Ready for Successful Yellow Metals Protection

Though yellow metal are known for their greater resistance to corrosion, a place still exists for their protection. Knowing the metals involved, the degree of corrosion hazards, and the specific benefits various corrosion solutions have to offer are the first steps to successful corrosion protection of yellow metals. Contact Cortec^® today for further assistance choosing a yellow metal corrosion inhibitor.

Keywords: yellow metal corrosion inhibitor, corrosion in electrical panel, electrical contact corrosion cleaner, electrical corrosion, corrosion inhibitors in heat exchangers, heat exchanger corrosion, Cortec, VpCI, export shipping solutions, copper corrosion

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Corrosion is an electrochemical reaction. It is therefore not surprising that truck and car batteries often experience extreme corrosion, accelerated by the electrical charge and corrosive acid inside. The resulting powdery grayish greenish buildup on battery terminals can interfere with the battery’s electrical connection to the wires-and potentially keep the vehicle from starting at all. While there is more than one method for cleaning and protecting corroded battery terminals, ElectriCorr^™ VpCI^®-239 is an easy way to do quick maintenance with a two-in-one product. Here’s how it works!

Dual Cleaning and Corrosion Protection

ElectriCorr^™ VpCI^®-239 is a multifunctional cleaner/corrosion inhibitor for outdoor or ventilated applications. It may be applied to electrical contacts, wires, and relays. Moisture-displacing, film-penetrating, and corrosion inhibiting characteristics allow it to be used in two main ways:

• Spraying ElectriCorr^™ on a dirty surface to easily clean and wipe away grease, grime, and other contaminants.
• Spraying a thin film of ElectriCorr^™ on a clean metal surface and leaving it to dry for ongoing corrosion protection.

ElectriCorr^™ VpCI^®-239 protects both ferrous and non-ferrous metals (e.g., brass contacts) and is safe to use with plastics, elastomers, and other non-metallics.

How to Clean and Protect Battery Terminals with ElectriCorr^™

It is always important to wear standard PPE such as safety glasses and gloves when cleaning a battery. For the most thorough cleaning, battery terminals should be disconnected first, following best practices for safety.* Basic cleaning and protection steps are as follows:

1. Spray ElectriCorr^™ VpCI^®-239 on exposed battery posts as needed to loosen corrosion products and wipe them away with a small brush or disposable cloth.
2. Spray a thin film of ElectriCorr^™ VpCI^®-239 onto the posts before reconnecting the battery terminals.
3. Reconnect battery terminals according to manufacturer’s safety instructions.
4. Clean corrosion off the outer battery terminals in the same manner as before, spraying ElectriCorr^™ VpCI^®– 239 as needed to loosen and help remove corrosion products.
5. Spray a final coat of ElectriCorr^™ VpCI^®-239 on the battery terminals and allow to dry for one to two hours to slow down future corrosion.

Other Places to Use ElectriCorr™

ElectriCorr^™ VpCI^®-239 can be an invaluable tool at large preservation projects, construction companies, or industrial service providers where fleets of vehicles, heavy equipment, or other battery-powered assets sit outside year-round. In addition to protecting battery terminals, ElectriCorr^™ VpCI^®-239 is a great cleaner/protector for a variety of other electrical/electronic components.

• Electric motors
• Outdoor generators and junction boxes
• Outdoor and indoor electrical outlets
• Ventilated electrical panels
• Other electrical contacts

Whether you just need to touch up your personal car battery or maintain a parking lot full of company vehicles, ElectriCorr^™ VpCI^®-239 is one way to quickly and easily clean away the corrosion to promote a good electrical connection and discourage the aggressiveness of corrosion in the future. Contact Cortec® to learn more about this cleaning/protection option for battery terminal corrosion!

Keywords: how to clean corroded battery terminals, how to prevent corrosion on battery terminals, how to prevent corrosion on electrical connections, how to prevent corrosion on a car battery, Cortec, ElectriCorr, electrical corrosion, fleet maintenance, car battery maintenance, car battery won’t start

*Be sure to consult manufacturer’s recommendations for safe handling and removal, which typically involves disconnecting the negative terminal first and reconnecting it last.

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It is not uncommon for a new oil and gas construction project to cost anywhere from $10 million for a basic rig to upwards of $500 million for FPSO projects. Megaprojects with a $25 billion price tag may spend hundreds of millions of dollars on spares alone. At such high stakes, even a small buying or management change can have a big impact on increasing or reducing project costs. Proper preservation and asset management with Cortec^® VpCI^® Technologies can therefore add up to substantial monetary savings coupled with smoother, safer startup and ongoing operations.

Forecasting of Oil and Gas Spares

According to Sonny Reeves (President of CGSI), who has worked on some of the largest oil and gas development projects in the world, a typical oil and gas construction job will buy an additional 10% (on average) of spares in three different categories:

1) Construction spares
2) Startup/commissioning spares
3) Insurance and operating spares
The reason is that some components are expected to fail prior to startup due to mechanical damage, manufacturing flaws, or corrosion. Without backup spares, the discovery of defective equipment at the time of installation or startup could be disastrous, especially in remote areas where delivery lead time is excessive—even if replacement parts were readymade. Forecasting spares by 10%, 12%, or 15% extra is therefore a normal part of risk management.

Reducing Excess Inventory by Spare Preservation

Since corrosion is a major culprit for component failure, rust prevention itself can reduce the number of spares needed. Considering how quickly the cost of spares adds up, a little planning and some good preservation materials could have significant ROI.

Preservation of Construction Spares

Proper preservation must start with primary equipment to ensure that high-dollar—often custom—assets such as heat exchangers, fractionation towers, tanks, and modules will survive the transit and storage period without corrosion. Basic preservation materials such as CorroLogic^® Fogging Fluid VpCI^®-339 for internal void space preservation, VpCI^®-649 for hydrotesting and layup, and MilCorr^® VpCI^® Shrink Film for external protection are relatively simple to apply and go a long way toward preserving assets in like-new condition so that fewer backups are needed at installation and commissioning.

Preservation of Startup Spares

Startup spares should be preserved along similar lines. Hydrotesting valves, pumps, and vessels with a good dose of VpCI^®-649 will help protect against the residual moisture that inherently gets trapped inside during hydrostatic testing. Fogging of voids with Vapor phase Corrosion Inhibitors is also beneficial because the protective vapors form a molecular corrosion inhibiting layer on metal surfaces until the enclosure is opened. VpCI^® Films and Bags with UV resistance serve multiple functions by trapping these vapors inside a space, creating a durable barrier to wind and rain, and actively inhibiting corrosion through their own embedded rust preventative chemistry. Protective coatings such as VpCI^®-391 are great for temporary protection on exposed metal surfaces such as flange faces.

Preservation of Insurance and Operating Spares

Once the facility moves from startup to full operation, the plant will continue to require backups or “operational spares” to ensure continued uptime. As in other stages, good asset management and preservation of operational spares are critical to keeping parts corrosion free and ready to install on short notice. It can also be good evidence of a proactive safety management plan. In either case, Cortec^® VpCI^® fogging fluids, films, and coatings again provide an excellent path to preservation.

Optimizing Project Planning and Engineering

Preserving spares at all three stages and documenting the process is a growing trend in asset management with promising results. As Sonny Reeves pointed out in regard to CGSI’s own digital data preservation tool, “It is critical to not only take care of the assets throughout their life, but to be able to provide detailed proof of care to stakeholders.”

This “proof of care” gives project owners a greater chance of reselling or transferring the spares to the next stage of the project rather than scrapping excess inventory and writing it off as a loss. It offers peace of mind and facilitates smooth operations. It can also mean significant savings up front by reducing the number of spares needed.

If these benefits seem more attractive to you than the costs of forecasting excess spare inventory, contact Cortec^® for trusted go-to corrosion solutions used in oil and gas projects around the world.

Keywords: overbuying of spares, oil and gas industry, oil and gas spare parts, cost of corrosion oil and gas, forecasting oil and gas spares, spare parts calculation formula, reducing excess inventory, Cortec, metal preservation, rust prevention

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