Hot Dip Galvanising (Cap: 91.2 MT/Day)

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)