HOT DIP GALVANIZING PLANT FOR STRUCTURAL STEEL AND PIPES
[EIRI/EDPR/1612] J.C. 413
INTRODUCTION
Batch hot-dip galvanizing, also known as general galvanizing, produces a zinc coating by completely immersing the steel product in a bath (kettle) of molten zinc. Prior to immersion in the zinc bath, the steel is chemically cleaned to remove all oils, greases, soil, mill scale, and oxides. Surface preparation is critical as zinc will not react with unclean steel.
After surface preparation, the steel is immersed in the molten (830 F) zinc bath. The bath consists of more than 98% pure zinc and the remaining 2% or less consists of additives – most commonly aluminum, nickel, and bismuth. These additives help with zinc fluidity and consumption, coating appearance, and other efficiencies. While in the galvanizing kettle, the molten zinc metallurgic ally reacts with the iron in the steel to form the coating.
Hot-dip galvanized coatings are used on many materials in myriad construction sectors from electric utility to artistic sculptures. Ranging in size from small parts such as nuts bolts and nails to large structural shapes, galvanizing is integral to North American infrastructure. Most commonly batch hot-dip galvanizing is used in atmospherically exposed steel; however, it is also used in fresh and salt water applications, buried in soil, embedded in concrete, and much more.
Size can be a limitation to the application of hot-dip galvanizing; however, the average length of zinc baths in North America is 40 feet and 55-60 foot kettles are common. Utilizing progressive dipping – immersing one portion of the product and then the other – significantly increases the maximum size that can be accommodated to nearly double the bath size.
COST ESTIMATION
Plant Capacity 10 MT/Day
Land & Building (600 sq.mt.) Rs. 61.20 Lac
Plant & Machinery Rs. 24.00 Lac
Working Capital for 1 Month Rs. 19.66 Lac
Total Capital Investment Rs. 1.15 Cr
Rate of Return 50%
Break Even Point 54%
CONTENTS
INTRODUCTION
COATING CHARACTERISTICS
ADVANTAGES OF GALVANIZING
DISADVANTAGES OF GALVANIZING
USES AND APPLICATION
MARKET SURVEY
INDIAN GALVANIZED STEEL INDUSTRY:
COIL COATING
NEW PROCESS IN COIL COATING
U-V CURABLE PRIMERS
CHROMATE COATING AND CHROMATE FREE COIL COATING
DEVELOPMENT OF CHROMATE FREE PRIMERS
ZINC COATING
THE FUNCTION OF THE ZINC LAYER ON BLOCK STEEL IS MAINLY THREE-FOLD:
TWO FOLD ADVANTAGE OF ZINC COATING
GALVANISING PROCESS
ELECTRO GALVANISING
SPANGLED PRODUCTS
SPECIAL QUALITY GALVANISED PRODUCTS
GALVANISED (GA) PRODUCTS
GALVALUME OR ZINCALUME
ADVANTAGES OF USING GALVALUME AS A SUBSTRATE ARE:
CORROSION RESISTANCE
YIELD ADVANTAGE
FORMABILITY
HIGH TEMPERATURE RESISTANT
THERMAL REFLECTIVITY
LIMITATIONS OF USING GALVALUME
GALFAN
GALBO SHEETS
GALVANO SHEETS
LIFE OF GALVANISED STEEL
RECYCLABILITY OF COATED PRODUCTS
ENVIRONMENT
INDIAN GALVANISED STEEL INDUSTRY
STRUCTURE OF INDIAN GALVANISING INDUSTRY
BROAD SECTORWISE CONSUMPTION OF COATED SHEETS IN INDIA
PRODUCTION OF COATED (GP/GC) SHEETS IN INDIA
IMPORTS
EXPORTS
APPARENT CONSUMPTION
SPECIAL APPLICATION OF COATED PRODUCTS
AUTOMOBILE INDUSTRY
COR ROSION PROTECT ION OF AUTOBODY PANELS
COSMETIC CORROSION
PERFORATION CORROSION
GALVANIZED REINFORCEMENT BARS
COLOUR COATED SHEETS
SUBSTRATE
THE SUBSTRATES USUALLY USED ARE:
PRIMER
TOP COAT
ROLE OF PRIMER
PRODUCERS OF COLOUR COATED SHEETS IN INDIA
ESTIMATED DEMAND
PERFORMANCE OF INDIAN GALVANISED STEEL INDUSTRY IN H1 OF FY'13
CONCLUSION
ACKNOWLEDGMENTS
GALVANIZING INDUSTRIES IN INDIA-PRESENT SCENARIO
B.I.S. SPECIFICATIONS
MANUFACTURING PROCESS
SURFACE PREPARATION
COATING STRUCTURE
COATING UNIFORMITY
COATING THICKNESS
CORROSION RESISTANCE-GALVANIZED COATINGS PROTECT STEEL IN THREE WAYS::
INFORMATION FROM GALVANIZERS ASSOCIATIONS
DE-LAMINATION
FIGURE 1: DE-LAMINATION
DRAINAGE SPIKES
FIGURE 2: DRAINAGE SPIKES
DISTORTION
FIGURE 3: DISTORTION
FLUX INCLUSION
FIGURE 4: FLUX INCLUSION
FLAKING
FIGURE 5: FLAKING
ROUGH SURFACE CONDITION
FIGURE 6: ROUGH SURFACE CONDITION
RUNS
FIGURE 7: RUNS FOR REJECTION.
RUST BLEEDING
FIGURE 8: RUST BLEEDING
WELD SPATTER
FIGURE 9: WELD SPATTER
WELDING BLOWOUTS
FIGURE 10: WELDING BLOWOUTS
WET STORAGE STAIN
FIGURE 11: WET STORAGE STAIN
DROSS INCLUSIONS
FIGURE 12: DROSS INCLUSIONS
COATING DEFECT (CONTINUED)
BARE SPOTS
FIGURE 13: BARE SPOTS
SAND EMBEDDED IN CASTING
FIGURE 14: SAND EMBEDDED IN CASTING
TOUCH MARKS
FIGURE 15: TOUCH MARKS
QUALITY CONTROL
LIST OF INDIAN STANDARDS RECOMMENDED:
PREPARATION OF THE METAL SURFACE FOR GALVANISING:
ALKALI DEGREASING -
ACID PICKLING -
SPECIFICATION FOR ZINC - GRADE – ZN 98.5%
BATH TEMPERATURE
TESTING AND INSPECTION
MASS OF COATING
DETERMINATION OF MASS OF COATING
5.6.1 STRIPPING SOLUTION
5.6.2. CALCULATION:
PROCESS FLOW CHART
PLANT LAYOUT
SUPPLIERS OF PLANT AND MACHINERY
HOT DIP PLANT
EOT CRANES
DG SETS
POWER TRANSFORMERS
ETP PLANTS
MEASURING AND TESTING INSTRUMENTS
AIR POLLUTION CONTROL EQUIPMENTS
SUPPLIERS OF RAW MATERIALS
ZINC
ZINC AMONIUM CHLORIDE
PICKLING CHEMICALS
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
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