Publish Time: 2025-10-27 Origin: Site
Corrosion is the silent enemy of industrial infrastructure. From power plants and offshore bridges to storage tanks and heavy machinery, rust quietly eats away at valuable assets, compromising safety, efficiency, and aesthetics. Traditional anti-corrosion methods—grinding, sandblasting, and solvent-based primers—often involve toxic chemicals, high energy consumption, and production downtime.
Enter the Water-Based Rust Converter, a breakthrough developed by VCI EP (Environmental Protection New Materials Co., Ltd.), that transforms the way industries approach corrosion prevention. This innovative solution not only eliminates the need for abrasive surface preparation but also aligns with global trends in green chemistry and low-carbon manufacturing. Together with VCI EP’s silicone-based anti-corrosion coating, it forms a complete, eco-friendly protection system that offers superior performance, simplified application, and a corrosion protection lifespan exceeding 10 years.
A water-based rust converter is not simply another anti-rust primer. It’s a reactive chemical system designed to transform active rust (iron oxide) into a stable, inert crystalline layer that adheres tightly to the metal substrate.
Traditional rust removal requires mechanical or chemical cleaning—grinding, sandblasting, or acid washing—which are time-consuming, hazardous, and costly. In contrast, VCI EP’s water-based rust converter uses advanced polymer emulsion technology combined with metal chelation and passivation chemistry.
When applied directly to a rusty surface, the converter reacts with iron oxide to form a dense chelated film. This film not only neutralizes existing corrosion but also provides a protective barrier against further oxidation.
Chelation and Conversion: The rust (Fe₂O₃ and Fe₃O₄) is chemically transformed into a stable ferric-organic complex, halting corrosion at its root.
Passivation: The surface becomes inert, significantly reducing electrochemical activity.
Polymer Film Formation: The water-based polymer emulsion forms a tough, flexible, and adherent coating that enhances subsequent paint adhesion.
VCI EP’s product sets a new standard for eco-friendly industrial coatings. Below are its defining characteristics:
Water-Based, Safe, and Non-Toxic
No flammable solvents, no toxic emissions, no explosive risk. The product is non-toxic, non-flammable, and non-corrosive, fully compliant with modern environmental standards such as RoHS and REACH.
Dual Function: Rust Conversion + Corrosion Protection
Unlike conventional primers that merely cover rust, this converter chemically neutralizes it. The resulting protective film serves as both a rust inhibitor and a primer layer.
High Coverage Efficiency
Each kilogram can cover 10–12 square meters, offering exceptional cost efficiency and reduced material waste.
No Grinding or Acid Washing Required
The converter penetrates deeply into rust pores, eliminating the need for heavy surface preparation. This reduces labor intensity and cuts overall project costs by up to 40%.
Strong Film and Excellent Adhesion
The cured layer forms a tough, flexible coating that bonds effectively with all types of water-based paints, including acrylic, epoxy, and polyurethane systems.
Reliable Technology, Scientifically Endorsed
Backed by leading research institutions and VCI EP’s proprietary technology platform, the converter represents a solid step toward smart, green corrosion management.
While the water-based rust converter handles chemical transformation and passivation, VCI EP’s silicone-based anti-corrosion coating provides the next layer of protection—a high-performance, weather-resistant shield designed for extreme industrial environments.
This silicone coating leverages an organic silicon resin system with high cross-linking density. The result is a coating that excels in UV resistance, high/low temperature endurance, aging stability, and chemical resilience.
Superior Chemical and Weather Resistance
The silicone matrix resists acids, alkalis, salt spray, and UV degradation, ensuring long-term durability in harsh environments such as coastal zones and chemical plants.
Single-Component, Fast-Curing Formula
Simplified application—no mixing, no complicated ratios. The coating cures quickly, reducing downtime and improving operational efficiency.
High Cross-Link Density for Superior Barrier Effect
The dense molecular network prevents moisture and ions from penetrating, dramatically reducing corrosion propagation.
Stable Performance in Extreme Conditions
Whether exposed to high UV radiation, freezing temperatures, or continuous moisture, the coating maintains its color, flexibility, and adhesion without chalking or cracking.
When used in combination, VCI EP’s water-based rust converter and silicone anti-corrosion coating create a chemically bonded + physically shielded system, achieving unmatched protection performance.
Independent laboratory tests show that this dual-system protection can easily withstand over 1,000 hours of neutral salt spray exposure, far surpassing conventional coating systems like epoxy zinc-rich primer + epoxy micaceous iron oxide + polyurethane topcoat.
The integrated VCI EP system extends service life by 2–3 times compared with traditional anti-corrosion solutions, ensuring long-term asset protection and lower lifecycle costs.
For power plants, substations, transmission towers, wind turbines, and flue gas desulfurization systems, downtime costs are enormous.
VCI EP’s system allows non-stop maintenance—no need for sandblasting or shutdowns—providing continuous protection while drastically reducing operational losses.
In high-salt, high-UV coastal environments—such as bridges, railings, light poles, cranes, and ship loaders—the silicone coating’s superior weatherability ensures long-term aesthetics and functionality.
Its flexible, impact-resistant nature accommodates vibration and stress without cracking.
For chemical plants, steel mills, mining operations, and cement factories, where corrosive gases, acid rain, and dust are common, the high cross-link density of the silicone coating delivers outstanding chemical and permeation resistance, even under constant exposure.
On steel roofs, facades, and coal conveyor galleries, this system provides an extremely cost-effective long-term protection solution. Compared to conventional alkyd or acrylic paints, lifespan is extended 2–3 times; compared to hot-dip galvanizing or heavy-duty epoxy systems, initial and application costs are lower.
For flanges, bolts, valves, irregular components, trusses, and high-altitude structures, the brushable and sprayable properties of the converter and coating ensure seamless coverage even in tight corners and cavities—eliminating the need for disassembly or sandblasting.
By extending maintenance cycles and eliminating abrasive preparation, total life-cycle costs can drop by over 50% in large-scale industrial applications.
Being water-based and solvent-free, the converter significantly reduces VOC emissions and carbon footprint, aligning perfectly with global carbon neutrality goals and corporate ESG standards.
With no toxic fumes or flammable solvents, workers can apply the product safely in confined spaces, minimizing health risks and improving construction efficiency.
Scenario:
A coastal power station faced severe corrosion on its transmission tower and smoke stack due to salt spray and acidic exhaust. Traditional sandblasting was impractical due to operational continuity and safety concerns.
Solution:
Step 1: Apply VCI EP Water-Based Rust Converter by brushing onto rusted steel. Within minutes, rust transformed into a stable, dark protective layer.
Step 2: Apply VCI EP Silicone Anti-Corrosion Coating as the top layer.
Results:
No production shutdowns
60% reduction in maintenance labor
Over 1,000-hour salt spray resistance
3× longer service life compared to epoxy-based systems
This case exemplifies how VCI EP’s eco-friendly system meets modern industrial demands for durability, safety, and environmental responsibility.
VCI EP continues to lead in the field of eco-conscious industrial coatings, guided by its mission to empower industries with sustainable materials.
By replacing solvent-based primers with water-based rust converters, and introducing long-life silicone coatings, VCI EP directly contributes to energy savings, emission reduction, and circular economy development.
The company’s R&D philosophy emphasizes precision, innovation, and craftsmanship—ensuring every solution not only meets performance benchmarks but also aligns with the world’s “dual carbon” goals (carbon peaking and carbon neutrality).
As industries transition toward sustainable development, water-based rust converters represent a paradigm shift in surface protection technology.
The innovation by VCI EP embodies the fusion of chemistry, material science, and environmental engineering, providing the perfect balance between high performance and ecological responsibility.
By simplifying processes, enhancing durability, and reducing carbon impact, VCI EP’s Water-Based Rust Converter and Silicone Anti-Corrosion Coating are redefining what modern corrosion protection can achieve.