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Zerust Rust Removers and VCI Film Prevent Corrosion of Heat Exchangers

Corrosion on Heat Exchanger

  • Corrosion on tube bundles and header faces is very common
  • Manufacturers try to use greases, oil, coatings and packaging but these approaches have largely been unsuccessful; and many of these approaches may not be feasible given the geometry of the heat exchanger components
  • Heat exchangers in use, when cleaned or refurbished, typically have little/no protection and are stored outdoors
  • Such corrosion can lead to
    • Maintenance cost increases for rework to fix the corrosion damage
    • Potential liabilities related to product failures in operation
    • Increase in operational costs due to unplanned delays


Zerust Rust Removers

  • Zerust’s AxxacleanTM rust and tarnish removers are powerful solutions for the rework and recovery of metal items
  • Zerust offers a range of technologies, from pH neutral products to more aggressive products that also inhibit flash corrosion on cleaned surfaces
  • Depending on the type of part/equipment being cleaned, the appropriate Zerust rust removers can be used as a dip, spray or brush on application

Zerust Vapor Corrosion Inhibitor Film

  • Zerust has pioneered the use of Vapor Corrosion Inhibitors (VCIs) impregnated in packaging materials to protect parts from corrosion
  • VCIs emanate from the packaging and adsorb onto the surface of metals creating a mono- molecular layer that disrupts corrosion
  • Being a vapor, the inhibitors penetrate all the nooks and crevices of the equipment
  • Zerust has multiple types of VCI film based on client application requirements
  • When the integrity of the packaging is maintained, Zerust VCIs can protect metal parts for 10+ years
  • The VCI in Zerust film is FDA approved for food applications and is non-toxic and safe to use

Heat Exchanger Preservation

  • Problem: Heat Exchangers whether new or refurbished, have a complex geometry that make them susceptible to corrosion while making traditional cleaning and preservation difficult
  • Solution: Zerust products make heat exchanger preservation simple with high strength VCI diffusers enclosed inside VCI film
  • Heat exchangers that are cleaned and stored indoors can be preserved with Zerust ferrous (yellow) film wraps without the need for the outdoor preservation film.
  • The VCIs release within the enclosure and penetrate the various voids including the insides of the tubes to protect from corrosion
  • Shrinkable UV resistant outdoor protection films provide an additional barrier layer
  • Desiccants between the two layers minimize humidity and facilitate long term preservation

Heat Exchanger Cleaning

  • Smaller heat exchangers can be similarly cleaned using custom baths
  • In addition to the external surfaces, the Zerust chemistry travels through the tubes and cleans the insides as well; calcium carbonate scale/deposits can also be removed
  • The process is quick and effective and the reusable Zerust products make the process economical