[0001] The present invention is related to zinc-containing corrosion inhibitor treatments
and treatment compositions. The ability of zinc to inhibit the corrosion of ferrous
metals is, indeed, well known. Accordingly, soluble zinc salts are vital ingredients
of many corrosion treatment programs. For example, U.S. 4,089,796 to Harris et al
discloses a corrosion inhibiting composition comprising zinc and hydrolyzed polymaleic
anhydride or soluble salt thereof and benzotriazole. Other exemplary patents disclosing
such zinc containing treatments are U.S. 3,432,428 to Wirth et al and U.S. 4,120,655
to Crambes et al.
[0002] An art-recognized major problem encountered with zinc-containing treatments, particularly
in cooling water, is the uncontrolled precipitation of zinc salts; because, to be
effective, the zinc must reach the surfaces to be protected in a soluble form. For
example, the use of orthophosphate in combination with zinc as a cooling water treatment
is well known as evidenced by U.S. 2,900,222 to Kahler et al wherein phosphate, chromate
and zinc are used in combination. The orthophosphate can be provided as an actual
addition, or as a reversion product from any one of complex inorganic phosphate, organic
phosphate or organic phosphonate. When orthophosphate and zinc are both present in
the water, zinc phosphate precipitation becomes a concern. Whether or not orthophosphate
is present, the zinc could precipitate in other forms,- for example, as zinc hydroxide
or zinc silicate. The solubility of the various salts, that is, the retention of the
respective salt constituents in ionic form, depends on such factors as water temperature
and pH and ion concentrations. Wirth et al states that although water temperatures
can vary from 32° to 200°F, lower temperatures of 32° to 80°F are preferred because
"zinc tends to remain in solution better in cooler waters." This patent further states
that alkaline waters, particularly above about pH 7.5, are 'relatively undesirable
because "the dissolved zinc tends to deposit out or drop out much more rapidly in
alkaline water." Similarly, Crambes et al points out that zinc salts are unstable
in neutral or alkaline water and will precipitate with phosphates. Thus, if any of
these conditions are present, the aqueous medium becomes prone to zinc precipitation.
Because of the formation of this zinc scale, many of the surfaces in contact with
the aqueous medium will foul and the amount of effective (soluble) corosion inhibitor
present in the aqueous medium can be significantly reduced.
[0003] Although the present invention is considered to have general applicability to any
aqueous system where zinc precipitation is a problem, it is particularly useful in
cooling water systems. Accordingly, the invention will hereinafter be described as
it relates to cooling water systems.
[0004] 4 There has existed for a long time the need for a zinc-containing corrosion inhibitor
treatment which overcomes the above- noted problems, and the present invention is
considered to fulfill that need.
[0005] According to the present invention, a corrosion inhibitor treatment for metal surfaces
exposed to an aqueous medium comprises (i) water-soluble zinc compound and (ii) a
particular type of water-soluble polymer composed essentially of moieties derived
from acrylic acid or derivatives thereof and hydroxylated lower alkyl acrylate moieties
(HAA). The treatment could additionally comprise (iii) water-soluble orthophosphate
and (iv) water-soluble chromate. It was discovered that, although the polymer demonstrated
no significant activity alone as a corrosion inhibitor, when it was combined with
a zinc-containing treatment the various ionic constituents of the treatment were unexpectedly
retained in their soluble form and a corresponding increase in corrosion inhibiting
activity was observed. The present invention is accordingly also considered to be
related to a method for inhibiting the formation of zinc scale in an aqueous medium.
[0006] The polymers according to the present invention are those effective for the purpose
which contain essentially moieties derived from an acrylic acid compound (AA), i.e.,

where R is hydrogen or a lower alkyl of from 1 to 3 carbon atoms and R
1 = OH, NH
2 or OM, where M is a water-soluble cation, e.g., NH
4, alkali metal (K, Na), etc; and moieties of an hydroxylated lower alkyl (C
2-C
6) acrylate (HAA) as represented, for example, by the formula:

where R
3 is H or lower alkyl of from 1 to 3 carbon atoms, and R
2 is a lower alkyl having from about 2 to 6 carbon atoms.
[0007] In terms of mole ratios, the polymers are considered, most broadly, to have a mole
ratio of AA:HAA of from about 1:4 to 36:1. This mole ratio is preferably about 1:1
to 11:1, and most preferably about 1:1 to 5:1. The only criteria that is considered
to be of importance with respect to mole ratios is that it is desirable to have a
copolymer which is water-soluble. As the proportion of hydroxylated alkyl acrylate
moieties increases, the solubility of the copolymer decreases. It is noted that, from
an efficacy point of view, the polymers having a mole ratio of AA:HAA of 1:1 to 5:1
were considered the best.
[0008] The polymers could have a molecular weight of from about 1,000 to about 50,000 with
from about 2,000 to about 6,000 being preferred.
[0009] The polymers utilized in accordance with the invention can be prepared by vinyl addition
polymerization or by treatment of an acrylic acid or salt polymer. More specifically,
acrylic acid or derivatives thereof or their water soluble salts, e.g., sodium, potassium,
ammonium, etc. can be copolymerized with the hydroxy alkyl acrylate under standard
copolymerization conditions utilizing free radical initiators such as benzoyl peroxide,
azobisisobutyronitrile or redox initiators such as ferrous sulfate and ammonium persulfate.
The molecular weights of the resulting copolymer can be controlled utilizing standard
chain control agents such as secondary alcohols (isopropanol), mercaptans, halocarbons,
etc. Copolymers falling within the scope of the invention are commercially available
from, for example, National Starch Company.
[0010] The hydroxy alkyl acrylate can be prepared by the addition reaction between the acrylic
acid or its derivatives or water soluble salts and the oxide of the alkyl derivative
desired. For example, the preferred monomer of the present invention is the propyl
derivative. Accordingly, to obtain the hydroxylated monomer, acrylic acid is reacted
with propylene oxide to provide the hydroxypropyl acrylate monomer.
[0011] The polymers of the invention may also be prepared by reacting a polyacrylic acid
or derivatives thereof with an appropriate amount of an alkylene oxide having from
2 to 6 carbon atoms such as ethylene oxide, propylene oxide and the like. The reaction
takes place at the COOH or COM group of the moieties to provide the hydroxylated alkyl
acrylate moiety.
[0012] The polymer prepared either by copolymerization of AA with hydroxy propyl acrylate
(HPA) or reaction of AA with propylene oxide would be composed of units or moieties
having the structural formulas:

where M is as earlier defined.
[0013] Illustrative water-soluble zinc compounds which are considered to be suitable for
use in accordance with the present invention are zinc oxide, zinc acetate, zinc chloride,
zinc formate, zinc nitrate, zinc sulphate, zinc borate, zinc chromate, zinc dichromate,
etc.
[0014] As already noted above, the treatment could further comprise orthophosphate. Indeed,
the use of zinc and orthophosphate together as a corrosion inhibition treatment is
well known. It has also already been noted that the orthophosphate could be provided
as an actual addition product, e
ig., sodium orthophosphate, or as a precursor compound such as complex inorganic phosphates,
organic phosphates or organic phosphonates which revert to orthophosphate in the water.
[0015] Illustrative examples of orthophosphate as an actual addition are monosodium phosphate,
and monopotassium phosphate. Any other water-soluble orthophosphate or phosphoric
acid would also be considered to be suitable.
[0016] The complex inorganic phosphates are exemplified by sodium pyrophosphate, sodium
tripolyphosphate, sodium tetraphosphate, sodium septaphosphate, sodium decaphosphate
and sodium hexametaphosphate.. Either the corresponding potassium or ammonium salts
or the corresponding molecularly dehydrated phosphoric acids such as metaphosphoric
acid or pyrophosphoric acid are considered to be suitable.
[0017] The organic phosphonates are exemplified by aminotrimethylene phosphonic acid, hydroxyethylidene
diphosphonic acid and the water-soluble salts thereof.
[0018] Organic phosphates are exemplified in U.S. 3,510,436.
[0019] The amount of each constituent added to the cooling water will, of course, be an
effective amount for the purpose and will depend on such factors as the nature and
severity of the corrosion problem being treated, the temperature and pH of the cooling
water and the type and amount of precipitation-prone ions present in the water.
[0020] - In terms of active zinc ion, as little as about 0.5 parts of zinc per million parts
(ppm) of cooling water are believed to be effective in certain instances, with about
2 ppm being preferred. Based on economic considerations, the amount of zinc ion added
could be as high as about 25 ppm, with about 10 ppm representing the preferred maximum.
[0021] In terms of active polymer, as little as about 0.5 ppm polymer is considered to be
effective, while about 2 ppm is the preferred minimum. Based on economic considerations,
the polymer could be fed in amounts as high as about 200 ppm, with about 50 ppm representing
the preferred maximum.
[0022] In terms of active product added, the orthophosphate or precursor compound thereof
could be fed in an amount as low as about 1 ppm, with about 2 ppm representing the
preferred minimum. Based on economic considerations, the maximum amount is considered
to be about 200 ppm. However, about 50 ppm is considered to be the preferred maximum.
[0023] Methods for feeding corrosion inhibitors to cooling water are well known in the art
such that details thereof are not considered necessary. However, due to rather severe
stability problems experienced when the polymer was stored at high concentrations
with the remaining components, a two or three-barrel treatment is recommended.
[0024] Compositions according to the present invention could comprise on a weight basis:
(i) about 1 to about 95% of water-soluble zinc compound, and
(ii) about 5 to 99% AA/HAA polymer of the total amount of zinc compound and polymer.
The preferred relative proportions are about 4 to 85% water-soluble zinc compound and about 15 to 96% polymer; while it is most
preferred that the compositions comprise about 5 to 70% zinc compound and about 30
to 95% polymer.
[0025] In those instances where orthophosphate is also present, compositions according to
the present invention could comprise on a weight basis:
(i) about 1 to 95% water-soluble zinc compound
(ii) about 5 to 99% AA/HAA polymer, and
(iii) about 1 to 95% orthophosphate (or precursor thereof) of the total amount of
zinc compound, polymer and orthophosphate.
[0026] The preferred relative proportions are about 5 to 85% zinc compound, about 15 to
95% polymer and about 5 to 85% orthophosphate. The most preferred relative proportions
are about 10 to 60% zinc compound, about 15 to 80% polymer and about 10 to 60% orthophosphate.
[0027] The cooling water preferably will have a pH of about 6.5 to about 9.5. Since zinc
precipitation problems most commonly occur at pH's above about 7.5, the most preferred
pH range is from about 7.5 to about 9.5.
It EXAMPLES
[0028] Illustration of Zinc Precipitation Problem
Example 1
[0029] As noted above, an art-recognized major problem encountered with zinc-containing
treatments, particularly in cooling water, is the uncontrolled precipitation of zinc
salts from the water. Even in the absence of orthophosphate in the water, the zinc
can form precipitates such as zinc hydroxide.
[0030] This point is illustrated by the zinc-solubility results of several tests conducted
in water containing no orthophosphate. The tests were conducted, inter alia, to determine
the solubility of zinc in the test water as a function of pH.
[0031] The following aqueous test solutions were first prepared:
Solution A: 1,000 ppm Zn++ obtained from 0.27 gram Zn·SO4 H20/100 ml
SCW7: 170 ppm Ca as CaC03, 110 ppm Mg as CaCO3 15 ppm Si02
[0032] The tests were conducted using the following procedure:
1. Prepare SCW7 (detailed in Example 5 below) and adjust its pH to 4 with concentrated HC1.
2. To 2,000 ml of the above solution, add the required amount of Solution A with stirring.
3. Add 100 ml of the solution from step 2 to a bottle and agitate.
4. Slowly adjust the pH to the desired value with dilute NaOH solution and record
pH.
5. Place the samples in an oven at the required temper- rature for 24 .hours, after
which time, filter through a 0.2 micron millipore filter.
6. Analyze the filtrate for soluble zinc and record final pH.
[0033] The results of these tests are reported below in Tables 1 and 2 in terms of soluble
zinc (ppm) remaining after 24 hours at various final pH values.

Example 2
[0034] The problem of zinc precipitation in cooling water is further illustrated by the
zinc-solubility results of additional tests similar to those in Example 1, but conducted
in water containing both zinc ions and orthophosphate ions.
[0035] The following aqueous test solutions were first prepared:
Solution A: 1,000 ppm P04-3, obtained from 0.400 gram Na3PO4·12H2O/100 ml
Solution B: 1,000 ppm Zn+2, obtained from 0.27 gram ZnSO4·H2O/100 ml
SCW7: Same as Example 1
[0036] The following procedure was used:
1. Prepare SCW7 and adjust its pH to 4 with HCT solution.
2: To 2,000 ml of the above solution, add the appropriate amount of Solution A, followed
by the appropriate amount of Solution B with agitation.
3. Add 100 ml of the solution from step 2 to a bottle and adjust the pH to 7.5 with
dilute NaOH with agitation.
4. Place the samples in an oven for 24 hours at the appropriate temperature.
5. After the 24 hour period, filter the solution through a 0.2 micron millipore filter.
6. Analyze the filtrate for Zn+2 and P04-3.
[0037] The results of these tests are reported below in Tables 3 and 4 in terms of ppm soluble
zinc and ppm soluble phosphate remaining after 24 hours at various final pH values.

Example 3
[0038] A series of tests were conducted to determine the efficacy of various materials in
retaining zinc-containing corrosion inhibition treatments in a soluble form. After
all, the corrosion inhibition efficacy of such treatments will, for the most part,
depend on the constituents remaining soluble.
[0039] The test water contained both zinc and orthophosphate ions, and the test procedures
were the same as in Example 2 but for a few different steps as follows:
1. Solution C comprising 1,000 ppm of active treatment was also used.
3. Add 100 ml of solution from step 2 to a bottle, add the appropriate quantity of
treatment solution (1 ml = 10 ppm), and adjust pH to appropriate value with dilute
NaOH with agitation.
[0040] The results of the tests were calculated in terms of % increase in retention of soluble
zinc ions and soluble phosphate ions vs. an untreated solution using the following
equation: % Retention =

where Sol. P0
4 = soluble P0
4 in ppm. Of course, a similar equation was used for zinc calculations.
Example 4
[0042] A further series of tests were conducted to demonstrate the efficacy of various AA/HPA
polymers in retaining soluble zinc in an aqueous medium. The tests were the same as
those of Example 3 except for the absence of orthophosphate from the test solutions.
[0043] The results of these.tests are reported below in Tables 7-13 in terms of ppm soluble
zinc retained in solution. For purposes of comparison with untreated test solution,
Table 7 should be compared with the results of Table 1 and Tables 8-13 should be compared
with the results of Table 2.
[0044] Visual comparisons of Table 7 with Table 1 and Tables 8-13 with Table 2 are provided
in the accompanying drawing.
[0045] In Fig. 1 are presented a series of graphs which contain comparisons of Table 7 with
Table 1 in terms of soluble zinc remaining in solution after 24 hours vs. pH of the
test water. As can be seen from the figure, the lowermost graph represents a no treatment
test wherein the zinc readily precipitates. In comparison, the higher graphs represent
various test solutions to which have been added the noted AA/HPA polymers. The polymers
were all considered to be efficacious in retaining soluble zinc in solution.
[0046] Remaini-ng Figs. 2-7 provide visual comparisons of respective ones of Tables 8-13
with Table 2. Fig. 2 compares Table 8, Fig. 3 compares Table 9, Fig. 4 compares Table
10, Fig. 5 compares Table 11, Fig. 6 compares Table 12, and Fig. 7 compares Table
13, all with Table 2 in terms of plots of soluble zinc remaining in solution after
24 hours vs. pH at various indicated treatment levels. The line marked "No Treatment"
in each figure represents the results of Table 2.
Example 5
[0048] Having already demonstrated both the zinc precipitation problem related to zinc-containing
corrosion inhibitor treatments in aqueous mediums and the resolution of this problem
by combining the treatment with AA/HAA polymer, the following test results are presented
to demonstrate, from a corrosion inhibition point of view, the benefits of the combined
treatments.
[0049] The tests were each conducted with two non-pretreated low carbon steel coupons which
were immersed and rotated in aerated synthetic cooling water for a 3 or 4 day period.
The water was adjusted to the desired pH and readjusted after one day if necessary;
no further adjustments were made. Water temperature was 120°F. Rotational speed was
maintained to give a water velocity of 1.3 feet per second past the coupons. The total
volume of water was 17 liters. Cooling water was manufactured to give the following
conditions:
[0050]

Corrosion rate measurement was determined by weight loss measurement. Prior to immersion,
coupons were scrubbed with a mixture of trisodium phosphate-pumice, rinsed with water,
rinsed with isopropyl alcohol and then air dried. Weight measurement to the nearest
milligram was made. At the end of one day, a weighed coupon was removed and cleaned.
Cleaning consisted of immersion into a 50% solution of HC1 for approximately 20 seconds,
rinsing with tap water, scrubbing with a mixture of trisodium-pumice until clean,
then rinsing with tap water and isopropyl alcohol. When dry, a second weight measurement
to the.nearest milligram was made. At the termination of the tests, the remaining
coupon was removed, cleaned and weighed.
[0051] Corrosion rates were computed by differential weight loss according to the following
equation:

where N = 3 or 4.
[0052] The cooling water was prepared by first preparing the following stock solutions:
Solution A - 212.4 g CaCl2·2H2O/1
Solution B - 229.9 g MgS04·7H2O/1
Solution C - 25.5 g HaSi03·9H2O/1
- Solution D - 85 g Na2CO3/1
Treatment Solutions - 1.7% solutions (1.7 g/100 ml)
Then, these solutions were combined using the following order of addition:
1: To 17 1 of de-ionized water add, with stirring, (a) 20 ml of Solution A, (b) 20
ml of Solution B and (c) 20 ml of Solution C.
2. Adjust pH to 6.
3. With stirring add treatment (except Zn+2).
4. Add o-P04 Solution (if used).
. 5. Adjust pH to 7.0 if necessary.
6. Add Zn+2 Solution (if used).
7. (a) For SCW7 adjust pH to 7.0.
(b) For SCW8 add 20 ml of Solution D and adjust pH to 8.0..
[0053] The results of these tests are reported below in Table 14 in terms of corrosion rates
in mils per year (mpy).

[0054] While the comparative test results were not so pronounced at pH = 7, the comparative
results at pH = 8 were considered to be rather dramatic. Even though the AA/HPA polymer
alone demonstrated little, if any, efficacy as a corrosion inhibitor, when combined
with the zinc-containing treatments, the combined treatments demonstrated significantly
enhanced results as corrosion inhibitors. For example, at pH = 8, the corrosion inhibition
efficacy of 30 ppm active polymer alone (86 mpy) and 10 ppm Zn
+2 alone (84 mpy) appeared to be non-existent as compared to the untreated system (82
mpy); however, when only 5 ppm polymer were combined with only 5 ppm Zn
+2, the corrosion rate decreased to 13.6 mpy.
[0055] Illustrative examples of stable aqueous compositions made in accordance with the
present invention are presented in Table 15 in terms of relative proportions (in weight
percent) of the various constituents. In these compositions, the water-soluble zinc
compound was ZnSO
4.H
2O and the orthophosphate was Na
3P0
4.12H
20. Since calculations were rounded-off to two places, not all compositions added up
to 100%. Stability is defined in terms of soluble constituents in solution after 24
hours at 120°F.
1. A composition comprising an aqueous solution of a water-soluble zinc compound,
characterised in that the solution also contains as a stabilizer a water-soluble polymer
comprising moieties derived from acrylic or water-soluble salt thereof and moieties
of hydroxylated lower alkyl acrylate, wherein the moieties of said polymer have the
following formulas:

where R is hydrogen or a lower alkyl of from 1 to 3 carbon atoms; R
1 is OH, NH
2 or OM where M is a water-soluble cation; R
2 is a lower alkyl of about 2 to 6 carbon atoms, R
3 is H or lower alkyl of from 1 to 3 carbon atoms and the mole ratio of x:y is 1:4
to 36:1, and further characterised in that on a weight basis said zinc compound comprises
about 1 to 95% and said polymer comprises about 5 to 99% of the total amount of water-soluble
zinc compound and water-soluble polymer.
2. A composition as claimed in claim 1, characterised in that on a weight basis said
zinc compound comprises about 4 to 85% and said polymer comprises about 15 to 96%
of the total amount of water-soluble zinc compound and water-soluble polymer.
3. A composition as claimed in claim 1, characterised in that on a weight basis said
zinc compound comprises about 5 to 70% and said polymer comprises about 30 to 95%
of the total amount of water soluble zinc compound and water-soluble polymer.
4. A composition as claimed in any one of claims 1 to 3, characterised in that said
polymer has a molecular weight of about 1,000 to 50,000.
5. A composition as claimed in claim 4, characterised in that said polymer has a molecular
weight of about 2,000 to 6,000.
6. A composition as claimed in any one of claims 1 to 5, characterised in that the
pH of said aqueous solution is about 6.5 to 9.5.
7. A composition as claimed in any one of claims 1 to 6, characterised in that the
mole ratio of x:y is about 1:1 to 11:1.
8. A composition as claimed in claim 7, characterised in that the mole ratio x:y is
about 1:1 to 5:1.
9. A composition as claimed in any one of claims 1 to 8, characterised in that the
polymer is a copolymer of acrylic acid or water soluble salt thereof and hydroxypropyl
acrylate.
10. A composition as claimed in any one of claims 1 to 9, characterised in that it
also contains a water-soluble orthophosphate or a precursor thereof.
11. A composition as claimed in any one of claims 1 to 10, characterised in that it
additionally comprises water-soluble chromate.
12. A composition as claimed in claim 10, characterised in that on a weight basis,
said zinc compound comprises about 1 to 95%, said orthophosphate comprises about 1
to 95% and said polymer comprises about 5 to 99% of the total amount of water-soluble
zinc compound, water-soluble orthophosphate or precursor and water-soluble polymer.
13. A composition as claimed in claim 10, characterised in that said zinc compound
comprises about 5 to 85%, said orthophosphate comprises about 5 to 85% and said polymer
comprises about 15 to 95% of the total amount of water-soluble zinc compound, water-soluble
orthophosphate or precursor and water-soluble polymer.
14. A method for reducing the amount of corrosion of metal surfaces in contact with
an aqueous medium prone to zinc precipitation characterised by adding to said aqueous
medium in addition to a water-soluble zinc compound an effective amount of a water-soluble
polymer as defined in any one of claims 1, 5, 6, 8, 9 and 10, wherein said zinc compound
is added in an amount sufficient to provide from about 0.5 to about 25 parts of zinc
ion per million parts of aqueous medium, and wherein said polymer is added in an amount
of from about 0.5 to about 200 parts of polymer per million parts of aqueous medium.
15. A method as claimed in claim 14, characterised in that said zinc compound is added
in an amount sufficient to provide from about 2 to about 10 parts of zinc ion per
million parts of aqueous medium, and said polymer is added in an amount of from about
2 to about 50 parts of polymer per million parts of aqueous medium.
16. A method as claimed in any one of claims 14 to 15, characterised in that said
aqueous medium is cooling water.
17. A method as claimed in any one of claims 14 to 16, characterised in that said
aqueous medium has a pH of from about 6.5 to about 9.5.
18. A method as claimed in any one of claims 14 to 17, characterised in that water-soluble
orthophosphate, . or a precursor thereof, is also added to said aqueous medium in
an amount of from about 1 to about 200 parts per million.
19. A method as claimed in any one of claims 14 to 18, characterised in that the aqueous
medium additionally comprises water soluble chromate.
20. A method as claimed in claim 18, wherein said orthophosphate or precursor thereof
is added in an amount of from about 2 to about 50 parts per million.
21. A method of inhibiting the formation of zinc scale in an aqueous medium containing
zinc ions under scale forming conditions, which method is characterised by adding
to said aqueous medium an effective amount for the purpose, of effective water-soluble
polymer as defined in any one of claims 1, 5, 6, 8, 9 and-10, and wherein said polymer
is added in an amount of from about 0.5 to about 200 parts per million parts of aqueous
medium.
22. A method as claimed in claim 21, characterised in that said aqueous medium is
cooling water.
23. A method as claimed in claim 22, characterised in that said aqueous medium contains
phosphate ions which have been added as a treatment.
24. A method as claimed in any one of claims 21 to 23, characterised in that said
zinc scale comprises at least one member selected from zinc hydroxide and zinc phosphate.