Detailed Project Report on Hot Dip Galvanizing Plant for Structural Steel and Pipes

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)