HOT DIP GALVANISING
[EIRI/EDPR/4532] J.C.: 2749XL
INTRODUCTION
Galvanization is the process of applying a protective zinc coating to steel or iron in order to prevent it from rusting. The term is derived from the name of Italian scientist Luigi Galvani. Galvanized iron (GI) sheets are steel sheets which are basically coated with zinc and include a range of hot dip galvanized and electro-galvanized steel sheets. Zinc weathers at a very slow rate, so the coating generally has a long life. Zinc has a greater electro-negativity than iron and hence provides cathodic (or sacrificial) protection to the steel. This results in the zinc corroding in preference to the steel if the coating is chipped or damaged to expose the base metal. Besides acting as galvanic protector, The other functions of the zinc layer are as follow:
• To retain the steel intact with its full initial strength.
• To provide the surface a more pleasing appearance.
• To increase the life of any suitable organic finishing system applied over it.
• To protect the steel from corrosive attack in most atmospheres, acting as a continuous and lasting shield between steel and the atmosphere.
COST ESTIMATION
Plant Capacity 91.2 MT/Day
Land & Building (2000 sq.mt.) Rs. 2.14 Cr
Plant & Machinery Rs. 8.54 Cr
Working Capital for 2 Months Rs. 4.72 Cr
Total Capital Investment Rs. 16.37 Cr
Rate of Return 24%
Break Even Point 64%
CONTENTS
INTRODUCTION
ADVANTAGES OF GALVANISING
THE USE OF GI SHEETS GIVES THE FOLLOWING ADVANTAGES.
USES AND APPLICATION OF GALVANISING
GI SHEETS ARE SHEETS ARE USED EXTENSIVELY IN VARIOUS APPLICATIONS SOME OF COMMON USES ARE GIVEN BELOW
B.I.S. SPECIFICATION
PROCESS FLOW CHART
GALVANISING PROCESS
PROCESS OVERVIEW
SOME OF THE COMMON TERMINOLOGY USED IN GALVANIZING PROCESS ARE AS FOLLOWING:
ASH –
DROSS –
FLUX –
OVER-PICKLING –
INHIBITOR –
GALVANIZING BATH –
ALUMINUM ADDITIONS –
COATING THICKNESS
THE METALLURGICAL BOND
HOT DIP GALVANIZING PROCESS
ALL GALVANIZING CONSISTS OF FOUR FUNDAMENTAL STEPS:
SURFACE PREPARATION:
DEGREASING:
CLEANING:
PICKLING:
AGITATION:
RINSING:
FLUXING:
GALVANIZING:
IMMERSION:
WITHDRAWAL:
WATER QUENCHING:
CENTRIFUGING:
THREAD BRUSHING:
POST TREATMENT:
STACKING:
5. INSPECTION
CHARACTERISTICS OF GALVANIZED SURFACES
6. QUALITY CONTROL
INSPECTION & TESTING
MARKET OVERVIEW
MARKET TREND
SUPPLIERS OF GALVANISING SERVICES
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF ZINC INGOT
SUPPLIERS OF CASTIC SODA
SUPPLIERS OF HYDROCLORIC ACID
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF HOT DIP GALVANISING PLANT
SUPPLIERS OF DG SETS
SUPPLIERS OF EOT CRANES
SUPPLIERS OF POWER TRANSFORMERS
SUPPLIERS OF ELECTRICAL PANEL
SUPPLIERS OF ELECTRIC MOTOR
SUPPLIERS OF COOLING TOWER
SUPPLIERS OF EFFLUENT TREATMENT PLANT (ETP PLANT)
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
SUPPLIERS OF AIR COMPRESSORS
SUPPLIERS OF PLATFORM WEIGHING MACHINE
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
SUPPLIERS OF SHOT BLASTING MACHINE
SUPPLIERS OF JIGS AND FIXTURE
SUPPLIERS OF SUBMERSIBLE WATER PUMP
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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