White Rust Removal &

Prevention
Removal of White Rust
As noted, white rust corrosion is
characterized as a localized/pitting
type corrosion and identified by
characteristic white deposits.
However, not all white deposits
found on galvanized steel surface are
due to white rust and not all
deposits, including zinc-rich deposits,
will result in localized/pitting
corrosion.
White Rust Evaluation
Evaluation need to be done to
determine the deposits are better left
alone or if removal is required.
Evaluation can include any or all of
the following :


White Rust Evaluation
1. Deposits analysis - determine the
inorganic content. It may be the
deposits are calcium based and not zinc
oxide.

2. Physical inspection of the surface under
the deposits - investigate to determine
if there is pitting corrosion resulting
beneath the deposit. Consider leaving
the deposit alone if pitting is not
observed.


White Rust Evaluation
3 Age of the equipment and of the deposits
- the deposits may be doing more good
than harm. A tower that is far along in
life expectancy with white rust that has
been present for years is probably better
off left alone.

Mechanical Cleaning Methods
Virtually all information recommends the
removal of the white rust by brushing with
stiff bristle brush (not metallic wire) and
then coating the damaged areas. If the
white rust build up is light or spotty, it
should be easily brushed off to allow for
the formation of the protective zinc oxide.
This process can be enhanced by the
addition of inorganic phosphate or by
reduction of the pH/alkalinity during the
re-passivation step.
Chemical Cleaning Methods
In mild cases the area should be brushed (using
a stiff bristle brush) with a mild cleaning solution.
Severe cases may require multiple applications of
a more concentrated cleaning solution along with
brushing.
Phosphoric acid is an excellent choice, although
other acids such as acetic, glycolic or citric have
been used with success.
Care should be taken when using these other
acids since they can chelate the base zinc
coating.
Overdose may strip the zinc coating from the
steel surface.
Prevention of White Rust in
New Cooling Tower
White Rust of galvanized steel tower
can be a difficult and expensive
problem.

The start up program for a new
galvanized steel cooling tower should
incorporate the following guidelines
to prevent white rust.
Prevention of White Rust in
New Cooling Tower
Minimize mechanical damage to he zinc
coating especially the flooded interior of
the tower where aggressive water
chemistry is most likely.

Before tower start up, the tower should be
made free of debris by sweeping or
flushing chemicals of extreme pH (<6 or
>9) as this can initiate zinc corrosion or
strip the coating completely.

Prevention of White Rust in
New Cooling Tower

Concentrated treatment program
chemicals should not be added to areas
where direct contact with tower surfaces
can occur. Always add chemicals to an
area of turbulence.

Generally speaking, pH level < 6 or > 9
will increase zinc corrosion significantly.
Prevention of White Rust in
New Cooling Tower

Carbonate and Hydroxide alkalinity
are the most corrosive toward zinc.

Acid conditions are to be avoided.
White Rust Prevention
White Rust may be prevented by several
methods including :

a) Pretreatment with an inorganic phosphate
passivation program (require minimum of
100ppm calcium as CaCO
3
and 400-450ppm
PO
4
)

b) Operating with the cooling water initially for 45-
60 days in the pH range of 7.0-8.0, moderate
hardness levels of 100-300 ppm as CaCO
3
, and
alkalinity levels of 100-300 ppm as CaCO
3
.
White Rust Prevention
If the cooling tower must be flushed
with acid or caustic type cleaners it is
imperative that a bypass piping loop
which isolates the cooling tower be
installed to prevent damage to the
tower.

White Rust Prevention
Additionally, soft water (<50ppm
calcium hardness as CaCO
3
) must be
avoided as should cooling water of
high alkalinity (>300ppm as CaCO
3

and > pH 9).

White Rust Prevention
The best practice for successful
cooling tower start up is to operate
the tower for at least 45 to 60 days
with a cooling water of pH between
7.0 to 8.0. This should be adequate
time for the protective basic zinc
carbonate layer to form.
Recommended Cooling Water
Operating Conditions
Parameter Range
pH 7.0-8.0
Chloride as Cl Less than 450 ppm
Sulfate as SO
4
Less than 1200 ppm
Alkalinity as CaCO
3
50-300 ppm
Hardness as CaCO
3
Minimum 50 ppm



Thank you