The mining industry faces persistent challenges from corrosion, which is a natural degradation process exacerbated by harsh environments. Consequently, corrosion impacts equipment, safety, and profitability. Therefore, implementing proactive solutions is essential. In addition, this blog explores how ZERUST®’s corrosion prevention and remediation products address corrosion challenges in the mining industry.

Corrosion Challenges in the Mining Industry: Prevention for Equipment in Use

Mining operations present challenging environments where equipment like loaders, drills, and mining trucks face constant exposure to corrosive factors such as humidity, dust, and temperature fluctuations. Effective corrosion prevention is essential to protect these high-value assets and ensure uninterrupted operations, minimizing the corrosion challenges in the mining industry.

Recommended ZERUST® Products for Active Equipment:

	AxxaCoat™ 90B HFS: This sprayable, high-flash, outdoor rust-preventative coating is specifically designed for long-term protection of machinery and equipment. AxxaCoat™ 90B HFS forms a durable matte black film that is slightly tacky when used indoors but cures to a hard, dry-to-touch surface when exposed to outdoor conditions. Protection: Provides up to two years‡ of outdoor protection and even longer indoor protection. Applications: Ideal for large assets such as machinery and metal structures exposed to outdoor environments. Removal: Easily removable with mineral spirits or kerosene, ensuring the equipment is ready for operation when needed.
	Axxanol™ Z-Maxx Series: The Z-Maxx Series includes a thick grease (NLGI 2) and a lighter viscosity option (NLGI 0) for greater spreadability. Both anti-corrosion greases offer robust corrosion resistance under extreme weather and salt-air conditions. Protection: Protects outdoor assets for up to one year‡ and indoor assets for up to three years‡. Applications: Ideal for heavy equipment with exposed metal components, providing lubrication and long-term corrosion protection. Removal: Easily removed using ZERUST® AxxaWash™ or commercial cleaners, ensuring quick reactivation of assets.
	Axxanol™ Spray-G: This sprayable rust preventative grease combines the protective power of grease with the convenience of a spray. It’s particularly suitable for complex shapes and hard-to-reach areas on machinery. Protection: Offers up to one year‡ of outdoor protection and up to two years‡ indoors. Applications: Ideal for mining vehicles, loaders, and other machinery exposed to challenging conditions. Removal: Easily applied and removed, ensuring quick and hassle-free maintenance.

Protecting Electronics from Corrosion Challenges in the Mining Industry

Sensitive electronics in mining operations, such as control panels, electrical cabinets, and other enclosed systems, are highly vulnerable to corrosion caused by humidity, condensation, and airborne contaminants. ZERUST® Vapor Capsules provide an effective solution for corrosion challenges in the mining industry by delivering corrosion protection directly within these enclosed spaces.

• How They Work:
  • ZERUST® Vapor Capsules release invisible, odorless, and non-toxic Vapor Corrosion Inhibitors (VCI) that settle on exposed metal surfaces, forming a protective molecular layer. This barrier prevents rust and corrosion, even in hard-to-reach areas.
• Applications:
  • Protects sensitive electronics in cabinets, control boxes, and enclosures, even while in use.
  • Effective for up to two years^‡ (depending on the model), ensuring long-term reliability of critical components.
• Benefits:
  • Easy to install: Simply peel and stick the capsule inside the enclosure.
  • Safe and non-toxic: Suitable for use in operational environments without risking damage to electronic components.
  • Compatible with various metal types, making it a versatile choice for diverse mining applications.

By combining advanced rust preventative coatings for heavy equipment with Vapor Capsules for electronics, ZERUST® provides a comprehensive corrosion prevention strategy that ensures operational efficiency and protects valuable assets in mining operations.

Storage Protection for Spare Parts and Tools to Address Corrosion in Mining

In the mining industry, keeping spare parts and tools on hand for extended periods is critical to maintaining continuous operations. Unexpected equipment failures or breakdowns can lead to costly downtime, and having readily available replacement components ensures that repairs can be made promptly, preventing production halts. However, storing these parts and tools in harsh environments presents challenges, as they are susceptible to corrosion. ZERUST® offers a range of innovative solutions to protect these vital assets during storage to help minimize corrosion challenges in the mining industry.

Why Long-Term Storage is Crucial in the Mining Industry:

• Operational Continuity: Immediate access to replacement parts and tools minimizes the risk of operational delays caused by equipment failure.
• Remote Locations: Mining operations often occur in isolated areas, where delays in procuring parts can significantly disrupt workflows.
• Cost Efficiency: Maintaining an inventory of spare parts reduces the frequency of emergency orders and mitigates downtime costs.

ZERUST® Storage Protection Solutions:

	Vapor Capsules: Portable and easy to install, Vapor Capsules are an ideal solution for protecting metals in sealed enclosures such as toolboxes and other enclosed spaces. How They Work: These capsules release invisible, odorless Vapor Corrosion Inhibitors (VCI) that create a protective barrier on metal surfaces, preventing rust and tarnish. Applications: Suitable for various metals, these capsules provide protection for up to two years‡ (depending on the model) in sealed enclosures. Benefits: Quick installation, non-toxic, and safe for use around sensitive equipment and electronics.
	ICT® VCI Film and Bags: ZERUST® ICT® VCI Film and Bags offer versatile protection for parts and tools of all sizes. These products combine durable packaging materials with advanced VCI technology. Features: The VCI molecules released from the film or bags protect metal surfaces from corrosion, while the durable material acts as a physical barrier against moisture, dust, and contaminants. Applications: Perfect for storing tools, machine components, and spare parts during long-term indoor storage. Benefits: Easy to use, available in various sizes, and can be heat-sealed for enhanced protection.
	ICT® VCI Paper: A cost-effective and eco-friendly solution, VCI paper protects parts and tools of all sizes from rust and corrosion during storage. How It Works: The paper is infused with VCI compounds that are released onto metal surfaces, creating a corrosion-inhibiting layer. Applications: Ideal for wrapping or interleaving between metal parts, tools, or components. Benefits: Lightweight, recyclable, and suitable for ferrous and non-ferrous metals.

Corrosion Challenges in the Mining Industry: Solutions for Structural Components

Critical structural components such as rock bolts, anchor bolts, and wire ropes are essential for maintaining safety and stability in mining operations. These components are often exposed to harsh conditions, including humidity, corrosive mine water, and environmental cracking, leading to corrosion fatigue and potential structural failures. ZERUST® provides advanced solutions to safeguard these critical assets against corrosion challenges in the mining industry.

	AxxaCoat™ 90B HFS: A durable, sprayable outdoor rust preventative coating designed for long-term protection in challenging environments. How It Works: AxxaCoat™ 90B HFS forms a tough, slightly tacky matte black film indoors or a hard, dry-to-touch surface outdoors, shielding metal surfaces from moisture, oxygen, and UV radiation. Applications: Ideal for large structural components such as rock bolts, anchor bolts, wire ropes, pipelines, and other exposed infrastructure. Benefits: Protects assets for up to two years‡ outdoors or longer indoors. Provides robust resistance to corrosion in extreme conditions. Easily removable with mineral spirits or kerosene for maintenance or reapplication.
	Axxanol™ Z-Maxx Series: Heavy-duty anti-corrosion grease solutions designed to protect components in extreme conditions. Features: Available in two formulations: a thick NLGI 2 grease and a lighter viscosity NLGI 0 grease for enhanced spreadability and light lubrication. Free of VOCs, barium, and heavy metals, ensuring environmental compliance. Applications: Best suited for anchor bolts, wire ropes, and other structural components exposed to severe weather, salt air, and corrosive environments. Benefits: Protects assets for up to one year‡ outdoors or three years‡ indoors. Ideal for mining applications with challenging environmental exposure. Easily removed using ZERUST® AxxaWash™ or commercial cleaning solutions.
	Axxanol™ Spray-G: A convenient, sprayable rust preventative grease ideal for protecting complex or hard-to-reach areas. How It Works: Axxanol™ Spray-G forms a protective coating that shields against moisture, oxygen, and corrosive elements, offering comprehensive coverage even on intricate surfaces. Applications: Perfect for rock bolts, anchor bolts, and wire ropes requiring efficient and thorough protection in mining operations. Benefits: Provides up to one year‡ of outdoor protection and two years‡ of indoor protection. Quick and easy to apply, saving time during maintenance. Easily removable for reapplication or further processing.

Temporary Corrosion Protection During Downtime in the Mining Industry

Idle equipment during seasonal or market-driven shutdowns is highly susceptible to corrosion due to exposure to environmental elements. Proper corrosion protection ensures that machinery and assets remain in optimal condition and are ready for immediate use when operations resume. ZERUST® offers a comprehensive range of solutions tailored to outdoor preservation needs that help minimize corrosion challenges in the mining industry.

	ICT®510-OPS Outdoor Preservation VCI Shrink Film: A premium shrinkable film that provides robust corrosion protection for large assets stored outdoors. How It Works: ZERUST® ICT®510-OPS combines durable 8-mil shrink film with Vapor Corrosion Inhibitor (VCI) technology. When heat-shrunk, the film conforms tightly around objects, protecting them from moisture, dust, and UV radiation, while the VCI molecules saturate the interior, preventing corrosion on metal surfaces. Applications: Ideal for large machinery, vehicles, and components exposed to outdoor environments, including mining trucks, crushing equipment, and conveyors. Benefits: Provides corrosion protection and UV resistance for up to three years‡ outdoors. Durable and weather-resistant for long-term preservation. Ensures hard-to-reach areas are protected with the VCI molecules.
	AxxaCoat™ 90B HFS: A high-performance rust preventative coating for extended outdoor and indoor protection. How It Works: AxxaCoat™ 90B HFS forms a tough, slightly tacky matte black film indoors and a hard, dry-to-touch surface when exposed to outdoor conditions. Applications: Protects large metal surfaces, such as pipelines, building structures, and outdoor equipment. Ideal for long-term storage and shipping. Benefits: Protects assets for up to two years‡ outdoors and longer indoors. UV-stable coating resists cracking and degradation under sunlight. Easily removable for maintenance or reactivation of equipment.
	Axxanol™ Z-Maxx Series: Heavy-duty anti-corrosion greases designed for extreme weather and environmental exposure. Features:  Available in thick NLGI 2 grease and lighter NLGI 0 for enhanced spreadability. Provides exceptional corrosion resistance under salt-air and high-humidity conditions. Applications: Protects outdoor machinery, exposed metal components, and equipment stored for long periods. Suitable for mining shovels, drills, and loaders. Benefits: Outdoor protection for up to one year‡; indoor protection for up to three years‡. Multipurpose combining lubrication with corrosion prevention. Easy to remove for maintenance or re-coating.
	Axxanol™ Spray-G: A sprayable rust preventative grease for convenient application on intricate machinery. How It Works: Axxanol™ Spray-G forms a protective barrier against moisture and other corrosive elements. Applications: Ideal for mining machinery, rock crushers, and other complex or hard-to-reach equipment stored outdoors. Benefits: Provides up to one year‡ of outdoor protection and up to two years‡ indoors. Quick and easy application for efficient maintenance. Easily removable, making equipment ready for immediate use.

Case Study: ZERUST® in Action

Challenge:
A major equipment supplier to the mining industry had a sharp increase in demand for their large-scale rock-crushing components. They needed to be able to ramp up production and store them on-site for up to two years. They no longer had sufficient inside storage for the additional inventory and needed an outdoor corrosion prevention system. This allows them to store the equipment outside, exposed to the elements.

Mining Corrosion Solution:

The company implemented ZERUST® ICT®510-OPS VCI Shrink Film as it provides outdoor corrosion protection for a minimum of three years and can withstand UV rays during that time. In addition to the VCI Film solution, ZERUST® also suggested that they apply a sprayable corrosion prevention coating (Axxanol™ Spray-G) as additional outdoor storage protection in case of any accidental rips or holes in the preservation film over time.

Result:
The customer has been extremely happy with the corrosion solutions provided by ZERUST®, as they were able to avoid any corrosion incidents for 5 years since implementing the ZERUST® preservation system.

Read the full case study here

Recovering Rusted Metal to Combat Corrosion in Mining Operations

Corrosion can sometimes take hold before preventive measures are applied. ZERUST® AxxaClean™ rust removers are designed to rework and recover rusted metal parts, restoring them to usability.

ZERUST® Rust Removal Solutions:

	AxxaClean™ ICT®625-RR:  A pH-neutral, acid-free chelating rust remover designed for mild to moderate rust removal. How It Works: AxxaClean™ ICT®625-RR reacts with iron oxide to eliminate rust from surfaces and hard-to-reach areas. The solution is ready to use and safe for both ferrous metals and yellow metals like aluminum. Applications: Ideal for cleaning machine components, small tools, and mildly rusted ferrous parts used in mining operations. Benefits: Gentle and non-acidic, ensuring minimal impact on metal surfaces. Works within 20 minutes to a few hours, depending on rust severity. Safe for use on aluminum and compatible with subsequent processes like painting or welding.
	AxxaClean™ 2048:  A moderate-acting, nonhazardous, safe rust remover effective for medium rust and tarnish removal on various metals. How It Works: AxxaClean™ 2048 is formulated with a pH of approximately 2.5 (similar to soda), making it safe and easy to handle. Additionally, it penetrates crevices and deoxidizes ferrous and non-ferrous metals, such as aluminum and magnesium alloys. Applications: Suitable for cleaning structural components, tools, and parts with medium rust or tarnish in mining environments. Benefits: Safe for use on metals, as well as non-metal components like paint, gaskets, and plastics. Eco-friendly formula minimizes disposal challenges. Leaves surface clean and ready for immediate painting, welding, or additional processing.
	AxxaClean™ 3048:  A rapid-acting industrial rust remover designed to tackle heavy corrosion and tarnish on ferrous and yellow metals. How It Works: AxxaClean™ 3048 is available in immersion and brush-on gel formulations, offering flexibility for heavy rust removal. With a pH of around 1, it penetrates deep into crevices and hard-to-reach areas, removing even the most stubborn rust. Applications: Ideal for heavily rusted mining equipment, large components, and tools requiring extensive restoration. Benefits: Effective for severe rust removal on complex geometries and large surfaces. Safe for use on most non-metal components, though testing is recommended for compatibility. Restores heavily corroded parts to usability, extending their service life.

Post-Rust Removal Recommendations:

• Rinse cleaned items with a 5% solution of ZERUST® AxxaVis™ HST-10 and dry with compressed air.
• Protect metals with ZERUST® VCI packaging films or rust preventative coatings to prevent future corrosion.

ZERUST® Solutions for Corrosion Challenges in the Mining Industry

Corrosion in the mining industry is a challenge, but ZERUST® offers comprehensive solutions to protect, preserve, and restore assets. Furthermore, from coatings for active equipment to rust removers for reworking metal, ZERUST® helps mining operations maintain efficiency, safety, and profitability.

Contact ZERUST® today to develop a corrosion management strategy for your mining assets!