Vappro Vbci the Solution for Corrosion Control: Solving Corrosion Problems with the Environment in Mind

By Dr. Nelson Cheng PhD

The global economic cost from corrosion is estimated to be more than US$2.5 trillion, or equivalent to 3.4% of the global GDP.

Corrosion costs the U.S. economy close to $300 billion per annum.
About 100 billion dollars these costs could be remediated by application of corrosion-resistant materials and the use of corrosion-related technical practices such as corrosion inhibitors.

A corrosion inhibitor is a chemical compound that, when added to a liquid or gas, decreases the corrosion rate of a metal, or its alloy that comes into contact with the fluid or vapour. These chemicals are both organic and inorganic compounds, which generally form a protective layer on the metal surface.

Some corrosion inhibitors contain heavy metals are harmful to human health, toxic to plants, environments, and animals. They also have adverse effect on the ecology of the receiving environment and on surface and ground water quality.

This book focuses on the use of Vappro VBCI Corrosion Inhibitors which are biodegradable, less toxic, and environmentally friendly. The authors believe in creating a cleaner, greener, and better tomorrow for our children and children’s children.

Lead Authors
Dr Benjamin Valdez Salas
Dr Nelson Cheng PhD (honoris causa)
Patrick Moe BSc, MSc, Grad Diploma

• Language: English
• Publisher: Partridge Publishing Singapore
• Release date: Dec 10, 2020
• ISBN: 9781543762181

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ISBN

ISBN: 978-1-5437-6223-5 (sc)

ISBN: 978-1-5437-6219-8 (hc)

ISBN: 978-1-5437-6218-1 (e)

12/10/2020

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Meet the Editors

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Dr Benjamin Valdez Salas was the director of the Institute of Engineering (2006–2013), Universidad Autonoma de Baja California.

He has a BSc in chemical engineering and an MSc and PhD in chemistry, and he is a member of the Mexican Academy of Sciences and the National System of Researchers in Mexico. He was a guest editor of Corrosion Reviews, in which he produced two special issues on corrosion control in geothermal plants and the electronics industry. He is a full professor at the Universidad Autonoma de Baja California (UABC). His activities include corrosion research, consultancy, and control in industrial plants and environments. He has published more than 350 publications, with almost 1,000 citations. He has received an NACE Distinguished Service Award. He has been a member of NACE for twenty-six years. He is the current technical director of the Magna Group of Companies.

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Nelson Cheng, PhD (honoris causa), graduated as a marine engineer under the United Nations Development Program Scholarship and received his doctor honoris causa from the Universidad Autonoma de Baja California (UABC).

He is recognised as Singapore’s leading inventor and the Singaporean with the highest number of patents from the Intellectual Property Office of Singapore. He owns several worldwide patents, including VCI Mineral Stone Paper. He has invented more than 500 chemicals, lubricants, and anti-corrosion products, with more than 230 products assigned with NATO Stock Numbers and marketed in more than thirty countries. He is the inventor of several technologies for corrosion protection, including Vappro VCI (vapour corrosion inhibitors) and Vappro CRI (concrete rebar inhibitors), molecular reaction surface technology (MRST), colloidal corrosion inhibitors (CCI), and heat-activated technology (HAT). He has written more than 120 research papers and technical journals, published by the National Association of Corrosion Engineers (NACE), the International Journal of Emerging Technology and Advanced Engineering (IJETAE), the International Journal of Current Trends in Engineering & Technology (IJCTET), Cambridge University Press, Academia.edu, ResearchGate, and IntechOpen; and he has co-authored several anti-corrosion books.

Nelson has received and accorded several accolades, including 2015 winner of the Asian Packaging Award; Top 10 Most Inspiring Entrepreneurs 2015; winner of the Global Star, Asia Star, and Singapore Star Packaging Awards 2014, 2015, 2016, 2017, 2018; Top Entrepreneur Award—Singapore Small and Medium Business Association; Asian Excellence Award 2014; and Top 20 Innovation Award 2013 from the Small and Medium Business Association.

He is a member of the Society of Tribologists and Lubrication Engineers (STLE), American Chemical Society (ACS), World Corrosion Organization (WCO), and European Federation of Corrosion (EFC).

Preface

Corrosion is a pernicious phenomenon that appears in engineering materials, infrastructure assets, and industrial equipment exposed to the atmosphere, water, and soil. The aim of this book is to produce a body of knowledge on the theory and practice of vapour corrosion inhibition so it can be used in the selection of corrosion inhibitors to prevent and/or minimise corrosion in natural environments and industrial facilities. Corrosion inhibitors are employed in different forms, such as emitters, pellets, powders, films, paints, aerosols, aqueous and solvent solutions, depending on their chemical composition: organic or inorganic.

They are also applied impregnated on papers or plastics, closed in pouches and sachets, or added to coatings and paints to form a barrier against the attack of corrosion agents. They are employed in many vital industries: automotive, offshore/onshore, water, military, marine, manufacture, oil and gas, electronics, and concrete structures. Vappro VBCI corrosion inhibitors are a special group of corrosion inhibitors that are related to the advanced field of ‘green chemistry’. The use of Vappro VBCIs vapour corrosion inhibitors (VBCIs) has expanded rapidly in the last decades and are frequently mentioned in the relevant literature and in professional congresses and conferences organised by international and national corrosion associations.

Special thanks to Dr Benjamin Valdez Salas, Dr Michael Schorr Weiner, Dr Nicola Nedev, Dr Ernesto Beltran Partida, Dr Juan Ricardo Salinas Martinez, and Mr Patrick Moe for their contributions towards the completion of this book.

Dr Benjamin Valdez Salas

Dr Benjamin Valdez Salas was the director of the Institute of Engineering (2005–2013), Universidad Autonoma de Baja California, Mexico. He has a BSc in chemical engineering, an MSc and PhD in chemistry, and is a member of the Mexican Academy of Science and the National System of Researchers in Mexico. He was the guest editor of Corrosion Reviews, in which he produced two special issues on corrosion control in geothermal plants and the electronics industry. He is a full-time professor at the Universidad Autonoma de Baja California. His activities include corrosion research, consultancy, and control in industrial plants and environments. He has published more than 350 publications with almost 1,000 citations. He received a NACE Distinguished Service Award. He has been a member of NACE for 30 years. He is the current technical adviser of the Magna Think Tank Group.

Dr Michael Schorr Weiner

Dr Michael Schorr was a professor (doctor honoris causa) at the Institute of Engineering, Universidad Autonoma de Baja California. He has a BSc in chemistry and an MSc in materials engineering from the Technion-Israel Institute of Technology. From 1986 to 2004, he was an editor of Corrosion Reviews. He is acquainted with the appreciation of VCI in industrial environments. In addition, M. Schorr was a corrosion consultant and emeritus professor in Israel, USA, Latin America, and Europe. He has published 410 scientific and technical articles on materials and corrosion.

Dr Nicola Nedev

Dr Nicola Nedev received the PhD degree in physics from the Institute of Solid-State Physics, Bulgarian Academy of Sciences, in 1990. He is a professor of semiconductor physics and head of the laboratory semiconductors, microelectronics, and nanotechnology with the Institute of Engineering, Universidad Autonoma de Baja California, Mexico. His research interests include nanostructured materials, semiconductors, and semiconductor device technologies.

Dr Ernesto Beltrán-Partida

Dr Beltrán-Partida obtained his bachelor’s degree in biological and pharmaceutical chemistry and his PhD in biomaterials sciences both with honours from the Universidad Autonoma de Baja California. He is member of the Science and the National System of Researchers in Mexico and professor of biomaterials science, tissue engineering, microbiology, and molecular biology at the institute of engineering of Universidad Autonoma de Baja California Mexico. He has authored different peer-reviewed articles and a book chapter. He is a member of the Magna Think Tank Group.

Dr Juan Ricardo Salinas Martinez

He is a mechatronics engineer specialised in automation and control from Instituto Tecnológico de Mexicali, with a master’s in corrosion chemistry and a doctorate degree graduate with honours in chemical engineering for Universidad Autonoma de Baja California. He has been project leader for research on semiconductor materials and corrosion in the electronics industry and president of NACE (National Association of Corrosion Engineers) Student Section, Mexico. Currently he is a professor and academic coordinator of the chemistry department at Universidad del Valle de Mexico, campus Mexicali, and consultor for the industry in the field of corrosion and materials.

Patrick Moe

Patrick Moe is the senior technical manager of Magna International Pte Ltd. He has a BSc in industrial chemistry and a graduate diploma and MSc in environmental engineering. His key responsibilities at Magna International are as follows: assisting the CEO in research and development of new products, finding out customers’ needs and develop customised new products, helping in synthesising new compounds by making appropriate modifications of known methods, recommending and implementing methods to increase the quality of products and service, and managing of hazardous raw materials.

Contents

Introduction

Chapter 1Combating Seawater Steel Corrosion via Colloid Formation

Chapter 2Prolonged Protection of Military Equipment and Vehicles Using Vappro VBCI Inhibitor

Chapter 3VBCI Corrosion Inhibitors and Its Applications

Chapter 4Application of VBCI Inhibitors in Humid and Saline, Natural, and Industrial Environments

Chapter 5Algorithm Used for the Development of Vappro VBCI Products Using a Combination Equations of Mathematical Physics Derived from Gas Law and Coefficient of Diffusion

Chapter 6The Effectiveness of VCI Anti-Corrosion Properties of Vappro VCI Inhibicard Coated with Vappro MBL2200 Using German Test Method TL 8135-002

Chapter 7Avoidance of Hydrogen Embrittlement during Rust Removal with Vappro VBCI 812

Chapter 8Combating Sulphide Stress Cracking with Vappro VBCI OP 529

Chapter 9Establishing the Vapour Inhibition Ability of Vappro VBCI 849 Using German Test Method TL 8135-002

Chapter 10Vappro VBCI Anti-Corrosion Manaement Program for Above Storage Tank (ASTs) and Underside of Bottom Plate in the Absence or Deficiency of CP System

Chapter 11Removing Rust and Corrosion through MRST (Molecular Reaction Surface Technology)

Chapter 12Vappro VBCI MBP 3000 Masterbatch Powder Compounding Nitrite-Free VCI Masterbatch Polyethylene Resin

Chapter 13Vappro VBCI MBR 1000 Masterbatch Polyethylene Resin for Extruding Anti-Corrosion PE Film, Shrink Film, and Stretch Film

Chapter 14Optimisation and Characterisation of Volatile Corrosion Inhibitor (VAPPRO 872)

Chapter 15The Effectiveness, Dosage, and Characterisation of Vappro (CRI) Concrete Rebar Corrosion Inhibitor in Wet and Dry Environments

Introduction

The objective of this book is to create a body of knowledge on the theoretical and practical aspects of vapour bio-based corrosion inhibitors (VBCIs) to prevent and/or to eliminate corrosion in natural environments such as water, air, and acids and in industrial facilities such as oil, natural gas, concrete, paints and coatings, electronics, and military equipment.

In response to the need for greater industrial environmental responsibility, Magna Group has expanded our VCI product range to include a new series of Vappro bio-based corrosion inhibitors (VBCIs), which are organic, biodegradable, and essentially non-toxic.

Vappro VBCIs effectively protect both ferrous and non-ferrous metals against corrosion by inhibiting the reaction between metals and corrosive mediums. Vappro VBCIs act by adsorbing either ions or molecules on to the metal surface, reducing the corrosion rate by blocking anodic and/or cathodic reactions.

Vappro VBCIs are available as oils, greases, liquids, powders, coatings, aerosols, spray cans, biodegradable films, foam pads, tapes, and in masterbatches.

The said vapour bio-based corrosion inhibitors (VBCIs) are applied in diverse forms, such as powders, pellets, aqueous or solvent solutions, and in impregnated papers; closed in pouches and sachets, and added to coatings.

Natural CIs are extracted by water or organic solvents from suitable plants. They represent the advanced trends of corrosion management based on green chemistry.

Chapter 1

Combating Seawater Steel Corrosion via Colloid

Formation

Nelson Cheng, PhD (Honoris Causa); Patrick Moe, BSc, MSc, Grad. Diploma

Magna International Pte Ltd,

10H Enterprise Road, Singapore 629834

B. Valdez and M. Schorr,

Universidad Autonoma de Baja California-UABC

J. M. Bastidas,

National Center for Metallurgical Research, CSIC, Spain

Abstract

The performance of a volatile corrosion inhibitor (VCI) on steel via colloid formation through its reaction with Ca and Mg ions in seawater was studied. The physical and chemical properties of seawater, with and without the VCI at different concentrations, were determined. The VCI’s efficiency was assessed, and its suitability for the steel system in seawater was indicated at an optimal concentration of 0.05%.

Introduction

Corrosion and degradation of materials are pernicious problems that affect environment quality, industry efficiency, and infrastructure assets.¹ ² All these diverse facilities and installations require products, methods, and techniques to protect against, mitigate, and prevent corrosion damage. Volatile corrosion inhibitors (VCIs) are one of the modern technologies used to manage corrosion for the benefit of the global economy.³

Seawater Corrosion

The sea is a dynamic system in permanent motion. Complex surface currents and winds blowing over its surface generate waves that reach the coast and its industrial facilities located there.

Seawater is a solution consisting of many salts and numerous organic and inorganic particles in suspension. Its main characteristics are salinity and chlorinity, and from the corrosion point of view, dissolved oxygen (DO) content that ranges from 4 to 8 mg/L depending on temperature and depth. Seawater’s minor components include dissolved gases—carbon dioxide (CO2), ammonia (NH3), and hydrogen sulphide (H2S)—from urban sewage contamination. The oceans house algae, bacteria, and phytoplankton that generate about half of the oxygen in the atmosphere.

Ocean surface salinity is determined by the balance between water lost from evaporation and water gained through precipitation. The salt concentration, particularly sodium chloride (NaCl), varies from 2.0 to 3.5% according to the sea location and added amounts of fresh river water. For instance, salinity of the Red Sea (an enclosed basin) at high summer temperatures is 4.1%, but salinity of the Baltic Sea is ~2.0% since many rivers feed into it.

Seawater is slightly alkaline, with a pH of ~8.0. When it is contaminated by acids (i.e. in coastal regions near power stations burning fossil fuels and generating acidic rains), the pH can drop to 6.0.

Corrosion Inhibitors

In recent years, the use of VCIs has rapidly expanded worldwide for numerous technological and industrial applications, such as cooling water systems;⁴ steel-reinforced concrete; protected storage of military and electronic equipment;⁵ acid pickling and cleaning;⁶ by the oil and gas industry; as additives to coatings, paints, and elastomers; and for corrosion avoidance in oil pipelines.⁷ ⁸ The importance and relevance of VCI technologies are evident by the many patents gathered in a recently published review.⁹

VCIs slow the rate of corrosion reactions when added in relatively small amounts to water. They are classified into three groups:

• anodic inhibitors, which retard the anodic corrosion reactions by forming passive films

• cathodic inhibitors, which repress the corrosion reaction (e.g. by reducing DO)

• adsorption inhibitors, such as amines, oils, and waxes, which are adsorbed on the steel surface to form a thin protective film that prevents metal dissolution.

A Colloidal Corrosion Inhibitor

A polymolecular VCI, VAPPRO 844, was studied, which is added to seawater as a powder, and then it converts into a colloidal suspension with nanoparticles dispersed in the water. These nanoparticles are adsorbed on the steel surfaces, and a thin protective film is formed. The performance of this inhibitor depends on physical, biological, and chemical factors. The factors under analysis for this study included solution hardness, alkalinity, conductivity, and pH. Other factors, such as DO, contribute as well but were not within the scope of this investigation.

It is proposed that the mechanism of colloidal formation functions by combining the inhibitor (CI) with Ca²+ ions present in seawater to form an inert colloidal particle that is cationic in nature, as shown in Equation (1):

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The formed colloidal particles adhere to the metal and prevent the onset of corrosion by preventing the loss of electrons. This causes the electrochemical cell to be incomplete, and corrosion cannot occur. The VCI powder was specially developed to combat corrosion on mild steel and iron structures in stagnant seawater found in ballast tanks of ships and rigs. In this study, the VCI was tested to establish its effectiveness and to determine