NRDC Technology offer - RUST CONVERTER

PLANT PARAMETERS
Capacity, TPA	150
Number of shifts	2
Working days / Yr.	300
Land Reqd., m2	150
Covered Area, m2	75
MANPOWER
Managerial	1
Skilled Worker	4
Unskilled Worker	5
RAW MATERIAL
Phosphoric Acid	Acetic acid
Manganese carbonate	Metal powder
UTILITIES(Per Annum )
Power, KwH	1200
Process water, KL	1500
Raw water, KL	1000
PLANT & MACHINERY
Polyethylene tanks	Deioniser

Rust, which is an oxide of iron, being ferrous does not resist further corrosive action with the result that corrosion continues until the whole piece gets converted to the oxide electro-chemically. When iron converts into oxide, volume increases 3 to 3.5 times. If few bristles are there and a paint or a primer has been applied over there, the coating will stop only outside of the surface, not inside under cutting. Electro chemically iron will convert into iron oxide and with the increasing volume it will break the paint layer and outside corrosion will come inside. Paint only resist corrosion till the layer is unbroken. Rust converter is a new concept in the method of painting. It is a common practice that before painting the surface should be prepared thoroughly by pickling or sand plasting or otherwise paint could be applied on the large structures which does not have any knock and corners. But Rust Converter could be applied by a brush on any rusted structure which is free from lose rust and any other foreign compound, and then the surface can be be applied by a layer of paint.. Rust converter converts rust electro chemically into a protective complex coating of phosphates, oxides etc. which resist further corrosion and prevents further under cutting. The total reaction takes about 2 hours when the surface is dry within 45 minutes and is ready to be painted. In this method there is no thickness loss of the structure, as pickling and sand blasting reduces the thickness of the structure and needs elaborate arrangements for safety and for safeguarding against health hazards. In comparison to pickling/sand blasting followed by a primer and paint, it gives better paint life and gives a good surface for further painting. Generally all types of paints could be applied on rust converted surface viz. alkyds, chlorinated rubbers, epoxies etc.

The process for the manufacture of rust converter consists of preparing a composition by mixing phosphoric acid, manganese carbonate and acetic acid and then a metal powder is added in suitable proportions to the above composition. The mixture is allowed to react for 30 minutes. The composition should be prepared just before its application. When applied on rusted surface it will convert rust into a black hard, protective coating in a period of two hours.

National Research Development Corporation, a Government of India Enterprise, is a premier technology transfer Corporation with four decades of experience. It has helped establish over one thousand projects in the small and medium scale sector. The supply of technologies and services to entrepreneurs extend both in the developing and developed countries like USA, Germany, Malaysia, Burma, Nepal, Senegal, Madagascar, Indonesia Philippines, Vietnam, Lanka, Kenya, Brazil, Bangladesh and Egypt.

Temperature resistance	150oC
Coverage	10 sq.m/litre
Mixing time	30 minutes
Reaction time	30 minutes
Drying time	35-45 minutes
Film thickness	4 to 5 microns
Pot life	8 to 9 hours
Storage	Several years, if the liquid base and the acceleration power kept separately