How We Improve the Hot Dip Galvanizing Process - PowerPoint PPT Presentation

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How We Improve the Hot Dip Galvanizing Process

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The process is environmentally friendly, protects steel, and reduces energy requirements. In addition, it increases the capacity of a galvanizing plant. Listed below are some of the most common improvements we've made to our hot-dip galvanizing process. – PowerPoint PPT presentation

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Title: How We Improve the Hot Dip Galvanizing Process


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How We Improve the Hot Dip Galvanizing Process
1
  • USS UPi

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  • Recent environmental concerns have made public
    and private organizations and organs of state
    administration more interested in green
    technologies. In a recent study, the
    organizations suggested including hot-dip
    galvanizing in the list of "green" technologies.
  • The process is environmentally friendly, protects
    steel, and reduces energy requirements. In
    addition, it increases the capacity of a
    galvanizing plant.
  • Listed below are some of the most common
    improvements we've made to our hot-dip
    galvanizing process.

3
Reduction of Consumption of Zinc and Natural Gas
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  • In the past decade, a series of innovations have
    been developed for the Hot Dipped Galvanized
    process to increase the sustainability of the
    industry. One of these innovations is an improved
    ash solidification technique that reduces zinc
    consumption while simultaneously improving steel
    corrosion protection.
  • To evaluate the effectiveness of the new method,
    process-based cost modeling was used to analyze
    the effect of different elements on coating
    morphology, growth kinetics, and structure. The
    leachate was analyzed and four parameters were
    measured pH, zinc concentration, chlorides, and
    dissolved substances.
  • In batch hot-dip galvanizing, the parts are
    loaded onto a rack containing 50 cut-lengths of
    steel. The process begins by cleaning the steel
    and immersing the entire load in a molten zinc
    bath. Once the steel parts are fully coated, they
    are removed from the tank and can be shipped to
    the job site or delivered to a paint contractor
    for application.

4
Improved Galvanization Quality
4
  • Hot-dip galvanizing protects the steel from
    corrosion and rusting. The service life of a
    coating of zinc is measured as the period between
    the first appearance of surface rust and the
    first occurrence of 5 rust.
  • The thickness of the protective zinc coating
    determines the corrosion protection provided. The
    single most important quality check in hot-dip
    galvanizing is the thickness of the zinc coating.
    Besides coating thickness, other aspects of
    inspection include continuity, adhesion, and
    appearance.
  • However, the effects of hot-dip galvanizing on
    the mechanical properties of steel may not be as
    clear-cut. It has been shown that the yield
    strength and tensile strength of steel
    significantly decrease after galvanizing.
  • Nevertheless, elongation A remains unchanged. The
    resultant change in the mechanical properties of
    steel is still an improvement in their
    performance. Hot-dip galvanizing, however, is no
    substitute for a thorough analysis of the metal's
    composition.

5
Elimination of Wastes
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  • The ash that is generated during hot-dip
    galvanizing contains high levels of zinc and
    other soluble substances. This study aims to
    immobilize these pollutants for safer disposal.
    Three binders were selected for the
    solidification of the waste.
  • A leaching test according to EN 12457-4 was
    carried out to assess the effectiveness of the
    process. Four parameters were measured in the
    leachate, including pH, zinc concentration,
    chlorides, and dissolved substances.
  • Hot-dip galvanizing involves the immersion of
    steel and iron products into molten zinc. This
    process is best suited for large, bulky items. It
    can be performed as a continuous process or in
    batches. The slag produced during this process is
    considered hazardous waste.
  • In addition, the slag must be treated separately
    to prevent any contamination from other elements
    in the slag. The zinc slag must be stored indoors
    away from moisture, rain, or chemical corrosion.

6
Increasing the Capacity of the Plant
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  • Improving production by enhancing the hot-dip
    galvanizing process is important for many
    industries. The process involves adding aluminum
    to the bath, which has an affinity for oxygen
    more than zinc. The aluminum forms a barrier to
    oxygen on the surface of the bath.
  • This barrier prevents oxidation and reduces the
    amount of zinc ash produced. This additive helps
    increase the capacity of the hot-dip dip
    galvanizing process by reducing the oxidation of
    steel.
  • In addition to increasing capacity, it can also
    increase the quality of galvanized coatings.
    Steels with a silicon content of 0.04 to 0.15
    percent are better suited for this process.
    Low-silicon steels, on the other hand, will
    result in a dull and mottled finish. A low
    silicon content will increase the growth rate of
    the coating, while higher-silicon steels will
    reduce the growth rate.

7
Reduction of Operating Costs
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  • The cost of maintaining a system to prevent rust
    is often based on the initial purchase price,
    which is of little use in assessing the overall
    economics of the system. Furthermore, rust
    prevention systems can require extensive
    maintenance, which can cause operational
    stoppages and incur additional costs.
  • Additionally, maintenance tasks may require the
    use of scaffolding and/or covers for the products
    or machinery. These variables vary according to
    the size and shape of the structures, which can
    affect both the cost of galvanizing and the ease
    of maintenance.
  • Reduction of operating costs during Hot Dipped
    Galvanized Steel can be achieved by optimizing
    the process. Continuous internal processing of
    the flux solution can keep the iron content of
    the bath at a minimum and reduce the production
    of disruptive residual products, such as zinc ash
    and iron zinc. As the cost of zinc and nickel
    continues to rise, these methods may offer an
    alternative way to reduce costs during
    galvanizing.

8
THANK YOU
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  • Address 2487 Industrial Pkwy W, Hayward, CA
    94545
  • Email info_at_ussupi.com
  • Website www.ussupi.com
  • Phone Number (800) 877-7672
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