Vci paper

Introducing:

Water-miscible corrosion protection agents for VCI-Paper

Fe

H2O O2

x FeO · y Fe2O3 · z H2O

Chemical corrosion

What is chemical corrosion?• series of reactions at the phase border• measureable structural change• may lead to total material destruction

Contact corrosion

steel stainless steel

H2O O2

OH-

e-

Mex+

What is contact corrosion?• series of reactions at the phase border, electrochemical reaction• measurable structural change• may lead to a total destruction of the material

met

alco

rros

ion

What is corrosion?

water

oxygen

salt

Photo creditU.l.:Dredge No.4, Wikimedia Commons, licensed under: CreativeCommons-Lizenz by-sa-2.0-de, URL: http://creativecommons.org/licenses/by-sa/2.0/de/legalcodeU.r.:Zeche Zollern, Dortmund, Germany , Wikimedia Commons, licensed under : CreativeCommons-Lizenz by-2.0-de, URL: http://creativecommons.org/licenses/by/2.0/de/legalcodeL.l.:Corroding iron machinery at the White Island sulphur mine, abandoned after a lahar killed all the workers in 1914 , Wikimedia Commons, licensed under : CreativeCommons-Lizenz by-sa-3.0-de, URL: http://creativecommons.org/licenses/by-sa/3.0/de/legalcodeL.r.: A rusty screw, Wikimedia Commons, licensed under : CreativeCommons-Lizenz by-2.0-de, URL: http://creativecommons.org/licenses/by/2.0/de/legalcode

Corrosion - Example

met

al

2-3

mm th

ick

laye

r (e.

g. b

ase

oil)

50-1

00 m

m a

dditi

onal

pac

kagi

ng

(e.g

. PE

-Foi

l)

activ

e pr

otec

tion

laye

r (e.

g.

addi

tives

)water

oxygen

salts

How does corrosion protection work?

INFLUENCE FACTORS

External influence factors

Rust Prevention

material

surface

packaging

transport conditions

storage conditions


Rust Prevention

material

surface

packagingstorage conditions



materials

aluminium

steel

iron

galvanized

cast

• corrosion tendency of materials• aluminium is easiest to protect• cast is the most problematical material


surface

• surface condition influences the corrosion tendency• clean and dry parts a optimal• Wet parts are in constant danger of corrosion

• clean• dry+• wet• dirty• processed-



• Transport overseas has the highest demands• day/night cylces with crossing of the dew point is

demanding for the rust preventative• Regional transport and direct processing is optimal

no transport

regional transport

national transport

transport across the

Alps

overseas on deck

overseas lower deck

Photo credit1.f.l: Petrofer Chemie2.f.l.: Baureihe 185, Wikimedia Commons, licensed under: CreativeCommons-Lizenz by-sa-2.0-de, URL: http://creativecommons.org/licenses/by-sa/2.0/de/legalcode3.f.l.: Postpanamax-Containerschiff Xin Shanghai auf der Elbe bei Hamburg (2007), licensed under: CreativeCommons-Lizenz by-sa-2.0-de, URL: http://creativecommons.org/licenses/by-sa/2.0/de/legalcode4.f.l.: MD-11F, Wikimedia Commons, licensed under: CreativeCommons-Lizenz by-sa-3.0-de, URL: http://creativecommons.org/licenses/by-sa/3.0/de/legalcode


packaging

• storage in closed systems, even though in combination with VCI-products is optimal for dry workpieces (beware of air humidity and humid parts!)

• open systems do not provide additional corrosion protection

• closed systems• additional foil/paper• VCI products+• no packaging• open systems-

Photo creditleft: http://www.1averpacken.de/cosmoshop/pix/a/n/1346670156-4434.jpg; Effective: 21.02.2015middle: http://www.vci-korrosionsschutz.ch/VCI-Korrosionsschutz/VCI_Korrosionsschutz_files/Kiste_mit_VCI-Folie_web_medium.jpg; Effective: 21.02.2015right: http://www.muhesa.de/s/cc_images/cache_2443028916.jpg?t=1411204810; Effective: 21.02.2015


storage conditions

• inside storage is optimal for corrosion protection• outside storage is demanding to the rust preventative• salt containing air near shore promotes fast corrosion

inside

sheltered

outside

near shore

Picture creditleft: Gdansk Nowy Port kregi, Wikimedia Commons, licensed under: CreativeCommons-Lizenz by-sa-3.0-de, URL: http://creativecommons.org/licenses/by-sa/3.0/de/legalcoderight: Warmband im Lager, Wikimedia Commons, licensed under: CreativeCommons-Lizenz by-sa-3.0-de, URL: http://creativecommons.org/licenses/by-sa/3.0/de/legalcode

• the film type influences the protection time• higher film viscosity improves the corrosion protection• Varnish-type films show long term corrosion protection• Choice is influenced by external factors as well as further

processing

Film types

not perceptible

oily

vaselinewaxy

varnish

SYSTEM OVERVIEW

System overview

1 10 100 1000 10000 1000001

10

100

1000

10000

film viscosity [mm²s-1]

corr

osio

n pr

otec

tion[

d]

dipping is possible

oils forsyntheticsolutions

thixotropic oils

oils

emulsifable oils

waxes

System overview

1 10 100 1000 10000 1000001

10

100

1000

10000

film viscosity [mm²s-1]

corr

osio

n pr

otec

tion[

d]

thixotropic oils

oils forsyntheticsolutions

oils

emulsifyable oils

waxes

solving – heating –varpourising - cooling

oils + soft waxes

outside,without shelter

outside,sheltered

inside,unpacked

inside,packed

1d 1w 1m 1y 10y

emulsion

no film

risk

hard waxes

+VCI +VCI

System overview

Corrosion protection concept

optimal rust preventativematerial

surface

packaging


storage conditions

protection time

workflow

VCI-Paper

PetroCor P1 PetroCor P1



VCI-method• VCI- Volatile Corrosion Inhibitor. Inhibitors are substances capable of inhibiting or suppressing chemical reactions. They may be considered the opposite to catalyst, which enable or accelerate certain reactions.

• The VCI method is an active corrosion protection.

• Volatile corrosion inhibitors are among the most efficient and cost-effective classes of means used to protect metals from atmospheric corrosion.

Mode of actiondue to is evaporation properties, the VCI substance (applied onto paper) passes relatively continuously into the gas phase an is deposited as a film onto the item to be protected (metal surfaces).

• independently of ordinary temperatures or humidity levels

• The mode of action wrapped in VCI paper.

Mode of action• wrapped in VCI paper.

• Metallic surfaces must be clean

• The VCI paper should be no further than 30 cm away from the item to be protected.

• Approximately 40 g of active substances por m3

• Airtight heat sealing is not required

• The mode of action dictates how VCI materials are used. At item to be protected is, wrapped in VCI paper.

PetroCo

r P1

PetroCo

r P1

PetroCo

r P1

Mode of action

German Technical Regulations for Hazardous Substances, TRGS 615 “Restrictions on the use of corrosion protection agents which may give rise to N-nitrosamines during use”

del Corral Sánchez, Rafael

del Corral Sánchez, Rafael

Comparison of advantages and disadvantages of the VCI methodFunctional advantages:

• Since the gas also penetrates holes and cavities.

• slight film-formation on the workpiece

• Corrosion inhibition can be controlled by the concentration of the emulsion

• The wrapping need not be provide with an airtight heat seal.

Comparison of advantages and disadvantages of the VCI method

Disadvantages:

• PetroCor P1 is only suitable for steels and stainless steel.

PetroCor

Product Suggested for Suitable for

PetroCor P1 Kraft paperHot-rolled, Cold rolled steel, coils or

plates, their cutting and punching parts, electrical steel, Carbon steel, stainless

steel, cast iron, galvanized steel

PETROCOR P1 is a solvent-free water-miscible rust preventive to finish special paper (VCI-paper: volatile corrosion inhibitor), which is used to protect steel and alloys. Mode of operation• low vaporization of contents and change into the gaseous phase• set up of protection atmosphere• performance of a protecting and active film Advantages• efficient inhibition of electrochemical corrosion reactions as a result of an active film• high affinity to steel although it is wet (migration)• protection of hollows and drill holes as a result of inhibitors out of the gaseous phase

Titan Paper Mill• Paper Mill in Russia.• Creping paper for steel covering during for metallurgy industry.• Technology that they are using was developed by themselves.• They use ready kraft-paper, wetting it and then drying with Yankee and crepping it.• They use urotropin (C6H12N4) and sodium nitrit.• Customers for this paper is big metal plants witch produce metals mostly in sheets.• Yankee temperature app. 80°C• In ready paper they have around 5g of active ingredients per sq m of paper

Titan Paper Mill

Yankee Cylinder

Kraft paper roll

Mix-Tank

Titan Paper Mill

• It’s needed to protect metal for the transportation period including transportation via ocean (few months)

• Wild range of temperature -40 +50 C. And paper itself can be kept few months before use.

• Humidity

• They have plan to produce 500t such paper per month.

TEST METHODS AND GLOBAL APPLICATION CENTER

Global Application Center and Test Field

Picture creditsAerial: Dr. Florian Treptow

outside storage

Inside storageoutside storage

sheltered storagePetrofer plant Hildesheim

Test-field

sample holder

Testfield

Test Methods: CH-Test

Condensation atmosphere with constant humidity (CH) according to DIN EN ISO 6270-2

Air temperature: 40±3°CAir humidity: ~100%

• continuous condensation on the specimen• no defined cycle-time

Suitable for: All types of rust preventives, cleaners, coolants…

Test Methods: AHT-Test

Condensation Climate with alternating humidty and air temperature (AHT) according to

DIN EN ISO 6270-2

DIN EN ISO 6270-2 Petroferfor 8 hours

Air temperature: 40±3°C 40°CHumidity: ~100% ~100%

for 16 hoursAir temperature: 18-28°C 23°CHumidity: <100% ~60%

• 100% condensation of the specimen for 8h; <100% condensation for 16h• cycle time: 24h

Suitable for: All types of rust preventives, cleaners, coolants…

Test Methods: AHT-Test

For different concentration of PetroCor P1 are given in combination in 5 cycles. • The concentration of the product:

• 5% Petrocor P1 in tap water. 1,0-1,5 g/m2

• 10% Petrocor P1 in tap water. 2,5-3,0 g/m2

Note: the individually packed parts (steel sheets) must be wrapped in plastic to avoid the loss of the vapor-phase to the outside.

Test Methods: Test panelsQ

We are using test panel from Q-LAB, the so called Q-PANELs.

MaterialSAE 1008/1010ASTM A1008ISO 3574 Type CR1Roughness: 25-65 micro-inchesSurface finish: dull matte

Compositionmax. 0.60% Manganesemax. 0.15% Carbonmax. 0.030% Phosphorusmax. 0.035% Sulfur

The measuremets of our panels and how we arrange them.

Test Methods: Test panels

Q

15.2cm

7.6cm

Test Methods: PETROFER-Test

for this Test is not required a climatic chamber.

• Procedure for each cycle (cycle time: 24hours):• Air temperature: 20+3°C • Humidity: ~100% For different concentration of Petrocor P1 are given in combination in 5 cycles. The concentration of the product: • 2,5% Petrocor P1 in tap water 0,3-0,5 g/m2

• 5% Petrocor P1 in tap water 1,0-1,5 g/m2

• 10% Petrocor P1 in tap water 2,5-3,0 g/m2

Test Methods: PETROFER-Test

The individually packed parts (steel sheets) must be wrapped in plastic to avoid the loss of the vapor-phase to the outside.

Reference Sample 2,5% PETROCOR P1 5% PETROCOR Titan-Paper

All results have been favorable as with our normalized steel sheets, as with the Titan-Paper steel sheets.

Other Test Methods

Test Methods: NSS-TestNeutral salt spray test (NSS) according to DIN EN ISO 9227

Air temperature: 35±2°CSaline concentration: 5%Collection amount: 187,5±62,5mL/(h·m2)

• hourly check of the specimen

Not suitable for water-miscible products!

Test Methods: Indoor StorageTests for indoor storage are performed in our test field. The climate is harder than for „real“ indoor tests.There is

…no humidity control… no temperature control

So the test panels have more or less the conditions of an outdoor storage but without factors like wind, rain and spray water.

Test Methods: Chip-Filter-TestDIN 51360/2: Evaluation of rustpreventive properties of water-miscible coolants

Realization: 2g sieved grey cast 25 chips on filter2g emulsion for wettingafter 2h removal of chips, rinsing of the emulsionevaluation after drying

26.11.2015 – International Training: Rusty Winter, Hildesheim

Introduction to the Global Application Center (GAC)

The idea behind the GAC

problem

• customer has a problematic process• customer has to fulfill certain specifications and

no possibility to test it

trial

• customer sends parts to Petrofer, different products/processes are tested

• customer visits Petrofer to accompany the trials

solution

• customer gets results with product recommendation

• customer buys product based on trials

Salt spray chamber

• VSC 450, 480 l

• Number: 1

• Actual use: Neutral salt spray test (DIN EN ISO 9227)

• Applicability: – Salt spray tests (DIN EN ISO 9227 - DIN 50021)– Condense climate tests (DIN EN ISO 6270-2 - DIN 50017;

EN ISO 9688 - DIN 50018)– Normal climate tests (DIN 50 014, Abs. 5 Room temperatur)

Salt spray chamber

Climate chambers

Relative humidity in %

Tem

pera

ture

in °C

• VC3 4034, 335 l

• Number: 2

• Actual use: Condense climate tests (DIN EN ISO 6270-2)

• Applicability:– Freely adjustable from -42°C to 180°C– From 10-95°C a relative humidity of 10- 98% is adjustable

Climate chambers

Rumed climate chamber

• Rumed 4101 350 l

• Number: 1

• Actual use: Condensation climates

• Applicability:– -30°C to +80°C– 10% to 95% relative humidity– Freely adjustable

Rumed climate chamber

Condensation climate chamber

• Number: 1

• Actual use: Condensation climates, Vapor phase corrosion tests

• Applicability:– Condensation climates– Vapor phase corrosion tests

Condensation climate chamber

outside storage

Inside storageoutside storage

sheltered storagePetrofer plant Hildesheim

Test-field

sample holder

Testfield

Thanks for your attention.

Rafael del Corral SánchezGruppe Papierchemikalien / Group Paperchemicals /Grupo Químicos para el Papel

31106 Hildesheim | Römerring 12–16 | P.O. Box 10 06 45 | GermanyPhone: +49 5121 7627 379 | Postfach 10 06 45Mobil: +49 151 14 05 38 55 | Email: [email protected] | Internet: www.petrofer.com

mailto:[email protected]

http://www.petrofer.com/

Vci paper

Automotive

Transcript of Vci paper