Providing Sustainable Green Technology Solutions 

Flagship India

Evapo-Rust Case Study and Cost Analysis
Problem: 
  • A large tubing wholesaler was storing tube stock in a non-climate controlled, 100,000 sq.ft. warehouse in the Chicago area.
  • The tubing rusted heavily in a short period of time. 
  • In order to remove the rust the owner considered physically removing the rust with unskilled labor and grinders.
  • He calculated the cost at $10 USD per 31-foot long tube.
  • The inside portion of the tube would be left rusted. 
  • Acid dipping was also considered.
  • Since acids were too dangerous to be allowed at the warehouse, the tubes would have to be sent out to a local pickling operation.
  • The cost of loading, shipping, pickling and return shipping was more than $10 per tube and also left the tubes weakened by hydrogen embrittlement.

Remedy:  
  • The owner decided on Evapo-Rust as the method of de-rusting the pipes.  
  • After purchasing a 31 ft long, 4 ft deep tank, he added 220 gallons of Evapo-Rust.  

Results:  
  • With the initial 220 gallons of Evapo-Rust, the wholesaler was able to de-rust 700 tubes completely.  
  • The total weight of the tubes was approximately 66,000 pounds.  
  • The cleaning cost per tube was $4.60 USD, saving $5.40 USD per pipe.  
  • The pipes were completely clean inside and out.  
  • The Evapo-Rust caused no health problems and incurred no disposal costs.

Comparison:
  1. Sandblasting cost - $0.15 to $0.25 per pound of rusted steel
  2. Pickling or acid cleaning Cost - $0.20 to $0.30 per pound of rusted steel
  3. EVAPO-RUST Cost Of Use - $0.05 to $0.06 per pound of rusted steel
Cost Considerations for Rust Removal
A number of important factors need to be considered when determining the cost of a rust removal solution.  
The total cost of the entire process is more critical than the specific cost of the agent by itself.  
In this regard, the following areas need to be considered when selecting the appropriate solution for a specific rust removal application.-    

Evapo-Rust Cost Analysis

  • Evapo-Rust™ is a cost effective alternative to the acid treatments and media blasts that have been used for years.  
  • Evapo-Rust™ is safe, easy to use, requires no special equipment, works quickly and efficiently, won’t harm other surfaces, has no disposal costs, and does not have any special Regulatory reporting requirements.  
  • The U. S. Army calculated that it cost $.04 per pound to de-rust.  ​This is consistent with other testing, and offers a lower cost of usage than other rust removal alternatives.
  • Human safety (safety should always be foremost). 
  • Potential harm to metal or other surface areas.
  • Effectiveness.    
  • Flammability.    
  • Ease of use.    
  • Completeness of de-rusting process (e. g. blind holes, crevices, complex geometries).    
  • Temperature control.    
  • Per unit cost of de-rusting agent. 
  • Average product cost per square foot of rusted surface.    
  • Ease of disposal.    
  • Cost of disposal.    
  • Regulatory reporting requirements.
  • Rust inhibition after use.
  • Special equipment required.    
  • Cost of equipment.    
  • Energy costs.    
  • Equipment maintenance costs.   
  • Special training required for operator.    
  • Speed of process.    
  • Damage from potential errors (e. g. part deterioration from overuse).