D. Abzalova, O.Koblanova , G.Abramova , D. Kluzhin, Sh.Duissebayev,

Z. Kerimbekova

Kazakhstan Republic Shymkent Institute of the Kazakh-Turkish University

Named after H.A. Yassaui.

Rust Modifier New Composition Development

Annotation

Varnish- paint materials plating is the most universal, efficient and accessible method to protect metals from corrosion. The materials mentioned protect about 80 % of all metal surfaces.

However, quality of the surface preparation before painting considerably provides for the longevity and efficiency of the varnish- paint materials protection. Losses for the surface preparation for the painting may comprise about 30-50% of the total painting costs, and in some cases they even may prevail the painting cost.

The researchers have developed an optimal rust modifier composition. Its usage in some cases provides for the painting technology simplification, to low the labour consumption, to improve the labour conditions, to prevent surrounding pollution, to improve the longevity of the varnish- paint plating, to decrease the varnish- paint materials consumption.

Hydrolyzed lignin, large-scale wastes of the hydrolyzed plants is one of the progressive types of the raw materials for developing a new rust modifier.

The developed rust modifier may be used for the steel surfaces painting preparation of different items and constructions in order to convert the corrosion products to the chemically resistant water insoluble compounds, directly connected with the metal surface.

Key words: environment, chemical resistance, lignin, rust modifier, metal construction, plating, varnish-paint material, corrosion, and longevity.

         1. Introduction. The most important tasks of the national economy are equipment cost effective decreasing, anti-corrosion protection and operational expenses decrease, highly reliable and necessarily long-lasting operation of the equipment.

         To meet the requirements we have to take some measures: and first of all to create effective protective plating. Metal protection plating operating longevity and efficiency depend on the surface preparation quality before painting.

         We have analyzed some home and foreign research reports concerning rust recipe ground modifiers   and as a result of our search the most progressive works are the following:

-         development and manufacturing of the compounds, which are effective when applied onto the corroded metal;

-         using of the new ‘minor’ additives, providing for the more active corrosion product interaction and for the corrosion process retardation as a whole as well;

-         utilization  of the film formers and modifying additives based on the different production wastes.

Rust modifier utilization is one of the methods to paint metal immediately along the rusted surface. This substance chemically interacts with the corrosion products and changes the modifiers into the layer which is held on the metal surface, retards the corrosion process and provides for its perfect cohesion with the varnishes and paints.

A great number of different rust modifiers have been developed; they differ in their compositions and mechanism of interaction with the metal corrosion products. Foreign modifiers are Kurast, E Formula /Great Britain/, Korroles, Korrolit, Oldorit,  Germany  and others.

Such corrosion modifiers as EVA-0112, EVA-01, GISI, P-1T, ¹ 444, PRL- agriculture and others have been widely used in the home industry for surface preparation with corrosion modifiers. However, they are mainly manufactured in the pilot plants. Many components’ supply is short, modifiers’ using is specific, so all this prevents from increasing the output.

II. Task setting. We have developed a new lignin corrosion product modifier [3,5,7], because many industrial enterprises lack corrosion modifiers greatly  due to their shortage and high cost of their components – former known PRL-agriculture / ammonia lignin, train-oil, ethyl silicate resin [1-2].

Corrosion modifier is the most progressive because it’s a new material and a protection means by complex raw material and by-products utilizing.

Rust modifier is manufactured from the cheap and accessible materials. Hydrolyze lignin is just the material and it’s a large-sized hydrolyze plant waste         (50,0 thousand tons per year) and soap stock ( 30,0 thousand tons per year).

Hydrolyze lignin has been selected as the main component of the corrosion product rust modifier, because this natural polymer macromolecule is poly-functional and the raw material stock is unlimited. Creation of the hydrolyze lignin corrosion product rust modifier was theoretically based on its capacity to form complex compositions with metals mainly with ferrous oxides and its compounds.

Taking into consideration the hydrolyze lignin macromolecule poly- functioning and its three-sized net and disordered structure we may expect the formation of the inner complex salt – helate compounds.

III. Results. Corrosion modifier consists of hydrolyze lignin, orto-phosphoric acid, drying oil, soap stock, mono ethanolamine and water. Corrosion modifier is a one – component oily dark mass.

Table 1 presents the technical performance of the corrosion rust modifier characteristics in comparison with PRL-agriculture.

Table1

Corrosion modifier technical performance

¹

Index title

Regulations

MP

PRL-agriculture

1

2

3

4

1

Colour

Dark-brown oily liquid

Dark-brown oily liquid

2

External appearance

After drying the film should be homogeneous, even, from light to dark brown.

3

Conventional viscosity at /20±0,5/0C on viscosimeter vz-4, not less than

12

25

4

Non -volatile substance mass part of, % not less

18-25

20-25

5

Density at /20±2/0C, g/ sm3

1,98

-

6

Ortho-phosphoric mass part % not more

7-14

8-14

7

Grinding degree, mkm, not more

30

30

8

Drying period to  3 degree, at /20±2/0C, not more

50-60

-

9

Modifying capacity / modified layer thickness/ mkm in the limits

80-120

80-100

 

IV. Conclusion. Corrosion modifier is used to process the surfaces covered with rust layer 80-120 mkm thick. Conversion process takes 10-16 hours at normal to and 10-15 minutes at to 100-110 0C.

After this the modified rust surface may be covered with the protective varnish-paint plating.

Rust modifier is not recommended for applying to the clean metal free of rust and for the rust surface with the scale and clean metal parts, formed as a result of rust mechanical conditioning. Rust modifier utilization in the national economy different branches simplifies the technology of the metal surface preparation for painting, increases the metal construction service life, decreases labour expenses and varnish – paint material consumption.

References:

1. D.V. Kluzhin, D.A. Abzalova, K. Sirmanova, G. Nakipbekova. Study of anti-corrosion plating on ENBC-xylitan ground // South Kazakhstan science and education. Series: Chemistry and chemical technology. – Shymkent: South-Kazakh State univ. – 2005. - ¹7(47). – P. 90-92.

2. D.V. Kluzhin, D.A. Abzalova,  Zh. N. Ibrayeva. Protective performance of ENBC-xylitan // Proc. of Intern. Research-pract. conference. - Shymkent: Shymkent Institute of Intern. Kazakh-Turkish univ. – 2006. – P. 249.

3. D.V. Kluzhin, E. Babayan, D.A. Abzalova. Development of a lignine rust modifier new composition based on Shymkent hydrolyze plant wastes // Proc. III-rd  regional students’ research conference.- Taras, 2005. – P.106.

4. D.V. Kluzhin, A.V. Shimelkov, D.A. Abzalova. High efficient prime of the rust modifier based on the manufacture wastes // Proc. XIII-rd  students’ research conference. - Shymkent: Shymkent Institute of Intern. Kazakh-Turkish univ.-2005. – P. 26-27.

5. D.V. Kluzhin, E. Babayan, D.A. Abzalova. Rational utilization of the South-Kazakh natural resources // All-Russia Students’ Research Practical Conference ‘Chemistry and chemical technology in the 21st century’. – Tomsk (Russia): Tomsky Polytechnic univ.- 2005.

6. D.V. Kluzhin, N.S. Tagayev, D.A. Abzalova. Corrosion protection and operation of the long-lasting constructions and equipment // University research and production - 2005. – Shymkent: KazAT &K, 2005.

7. D.V. Kluzhin, G. Nakipbekova, D.A. Abzalova. Complex utilization of the South-Kazakhstan microbiology industry wastes // Proc. III-rd regional students’ research conference.- Taras, 2005. – P.109-110.