Hot-Dip Galvanizing Sector

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  1. INFORMATION ABOUT COMPANY

As Ateş Refrakter (Fire Refractory) we have gained the trust of our customers by carrying out successful businesses in project, product selection, supply and application in the associations since 2011. We will continue to serve our valued customers in technical support issues such as project, product procurement, heat insulation calculations, refractory installation (including all over Turkey and abroad). It is an honor to serve you with a much wider range of products with your support.

GENERAL HEADLINES

  1. GALVANIZATION HISTORY

 

  1. PRODUCTION FLOW

 

  1. INVESTMENT PLAN
  • CAPACITY
  • LAND
  • CONSTRUCTION
  • MACHINERY EQUIPMENT
  • RAW MATERIAL
  1. INVESTMENT COSTS

 

  1. HOT DIP GALVANIZED MARKETS

 

  1. OPERATING COSTS AND PROFITABILITY ACCOUNTS

 

 

  1. HISTORY OF GALVANIZATION

 

Luigi Galvani, who lived between 1737 and 1798, was professor of anatomy at the University of Bologna in 1775. During the research, while the frog was experimenting on the nervous and muscular system, he saw the frog move when the metal touched the lifeless frog. He then discovered the electrochemical connection that metal created on living things. He intensified his work on this idea. He published his research in 1971 and compiled it. In science, this research was the cause of great debate. Volta came up with an idea against this finding. He thought it originated from a metallic arc. As a result of these discussions, electrotherapy was started to be investigated by giving a direct current to the living being.

 

Alessandro Volta (1745-1827) was very influential in Galvani’s ideas and works. He developed the idea that electrical relations of different metals exist and energy can be produced in this relation. He has worked extensively in this direction. As a result of his work, he discovered the electrical energy nascent in relation of copper and zinc and continued to work on converting it into a package able energy (battery). And in 1799, Volta’s galvanic-based battery was accepted by the Royal Institute.

 

Humphry Davy (1778-1829) began to work on the reactions and results of different metals with different chemical properties that emanated from Volta’s experiences. Volta was mainly concentrated in the energies coming from the contacts of different metals. However, the coexistence of two different metals produced a chemical reaction. And this reaction was causing some sort of electro coating. Davy experimented with the resulting platinum cathode galvanic potassium batteries. In this way, he had the idea that a metal can be covered with another metal.

 

Michael Faraday, another British chemist working with Humphry Davy, observed in 1813 that the direct current generated by the reactions of the metals in the stack was followed by a chemical electrolytic pathway, which made his science base come alive. This law is known as the Faraday Electrolysis Law. And they still do not suffer from corrosion of different metals; they lose intensity (ASTM G102) in the light of this information.

The first official zinc coating experiment, which was carried out by immersing the molten zinc past the records, was conducted by French chemist P.J. Malouin was presented in 1742 by the Royal Chartered Company.

 

 

In 1836, another French company Stainlaus Tranquille Modeste Sorel patented zinc-plated iron and 9% sulfuric acid cleaning and surface treatment with aluminum chloride. A year later, in 1837, the British Patent Institute approved this method. In 1850 the British galvanizing industry carried out galvanizing 10,000 tons a year.

 

During the first years of galvanization, large steel structures were used to protect corrosion. Steels made especially in difficult-to-reach areas are being used with the advantage of easy pre-assembly coating and long service life, due to the easy rusting of steel wire in power transmission lines. Over time, technological progress has led to parallel increases in galvanizing as steel usage in the world increases due to the ease of workability of the steel.

 

  1. PRODUCTION FLOW

 

The galvanizing process mainly consists of four main parts: preliminary preparation, flux bath, galvanizing pool, cooling. In detail;

 

Preliminary preparation: The surfaces of galvanized materials must be clean. For this reason, it is necessary to remove the dirt and scale layer. Two kinds of chemicals can be used for this. They are composed of Sulfuric Acid and HCl Acid at 30% temperature, depending on the temperature and the usage temperature is room temperature. The dirt on the material is kept in the preparation pool according to the amount of rust. The cleaned material is rinsed with water before going to the flux pool.

 

Flux Bath: After the preliminary treatment, the rinsed material is immersed in the flux pool. The duration is 10 minutes in the theoretical calculation but 1-2 minutes is sufficient in practice. Flux can work at room temperature but it is healthier to work at certain temperature. The chemical coatings to be added to the flux can be made more homogeneous.

 

After fluxing, the material to be galvanized can be subjected to a drying process. However, in areas with a closed galvanized pool, it may not be necessary to dry them because of the slowdowns that occur before they dry out.

 

Hot Dip Galvanization: Molten zinc at 445-465 Co temperature and Al, Sn, etc. in varying proportions Pre-preparation into the pool containing elements and immersing the material from the flux pool. The immersion time is carried out by keeping the amount of immersed material for a certain period according to the metal thickness and the desired coating thickness.

 

Cooling:  Can optionally be applied to increase the speed of the stacking and storage phase after the materials are galvanized.

The important thing here is the operation and layout of the crane installation. Besides, it is one of the most beautiful sides to work in the hot dip galvanizing sector instead of being qualified.

  1. INVESTMENT PLAN

For the hot dip galvanizing process, three types of galvanizing pot sizes are proposed according to the hot dip galvanizing markets we will specify later.

Type 1: hot dipped galvanizing pot with dimensions of 6300x1500x1500 mm;

  • Capacity:

1,000 tons / month

  • Land:

The factory will be established on 10.000 m2 land.

  • Construction:

1- Administrative Office: 1000 m2

2- Inventory of incoming material: 1200 m2

3-Equipment area: 3000 m2

4-Maintenance, packing and stocking space: 1800 m2

5-Waste, maintenance, repair and raw material stock area: 600 m2

6-Green area: 2400 m2

  • Machinery Equipment:

Cranes

Acid Tanks

Stock and Carrying Acid Tanks

Rinse Water Tank

Flux Tank

Hot dipped galvanized pool

Compressor

Electric electronic control room

Quality control equipment and room

Electronic scale

Fuel tank

  • Material:

For the filling of 86 ton galvanized pot 99.99% – 98.5% ingot zinc

25 tons stoke ingot zinc

Once the amount of alloying required for the galvanizing furnace is reached, 1 tonne of alloy will be used per month.

Type 2: Hot-dip galvanizing pot dimensions of 8500x2000x1500 mm

  • Capacity:

1,600 tons / month

  • Land:

The factory will be established on 12.500 m2 land.

  • Construction:

1- Administrative Office: 1000 m2

2- Inventory of incoming material: 1600 m2

3-Equipment area: 4250 m2

4-Maintenance, packing and stocking space: 2100 m2

5-Waste, maintenance, repair and raw material stock area: 850 m2

6-Green area: 2700 m2

 

  • Machinery Equipment:

Cranes

Acid Tanks

Stock and Carrying Acid Tanks

Rinse Water Tank

Flux Tank

Hot dipped galvanized pool

Compressor

Electric electronic control room

Quality control equipment and room

Electronic scale

Fuel tank

Forklifts

  • Material:

For the filling of 165 ton galvanized pot 99.99% – 98.5% ingot zinc

40 tons stoke ingot zinc

Once the amount of alloying required for the galvanizing furnace is reached, 1,3 tons of alloy will be used per month.

Type 3: Hot-dip galvanizing pot dimensions of 12000x2200x1500 mm

 

  • Capacity:

3,000 tons / month

  • Land:

The factory will be established on 16.000 m2 land.

  • Construction:

1- Administrative Office: 1000 m2

2- Inventory of incoming material: 2200 m2

3-Equipment area: 5750 m2

4-Maintenance, packing and stocking space: 2600 m2

5-Waste, maintenance, repair and raw material stock area: 1250 m2

6-Green area: 3200 m2

  • Machinery Equipment:

Cranes

Acid Tanks

Stock and Carrying Acid Tanks

Rinse Water Tank

Flux Tank

Hot dipped galvanized pool

Compressor

Electric electronic control room

Quality control equipment and room

Electronic scale

Fuel tank

Forklifts

  • Material:

For the filling of 260 tones galvanized pot 99.99% – 98.5% ingot zinc

65 tons stoke ingot zinc

Once the amount of alloying required for the galvanizing furnace is reached, 1.9 tons of alloys will be used per month.

  1. HOT DIPING GALVANIZED MARKETS

ENERGY SECTOR

Power transmission lines are at the forefront of leading freight products for galvanization. The installation in Iraq 132 Kv 400 Kv and 220 Kv is done. Depending on the geological situation and weather conditions, the poles are erected at intervals of 25 meters, 50 meters and 100 meters. The raw material of these pillars is that the casts produced from continue castings are rolled into ingots. Corner irons shaped in dimensions of 30, 40, 50, 60, … 120 are the main materials used in the construction of power transmission lines. Their dimensions are variable, usually 6 meters. There are occasional angles made of 8 meters feet. That leads us to the selection of the size of the furniture. The flag used in the construction of the energy transmission line with the used materials is made hot dip galvanized including the bolt and the bolt and the tensioner set, all the hardware materials, bolts and nuts, the flag used to form the thick hair and open the holes by cutting the corners around 8-50 cm. The main cause of the galvanization is the extension of the life of the iron. And, in certain times of renewal of energy transmission lines, electricity loss can reach 8-10%, which is sometimes about 40%. For this reason, energy transmission lines will be installed and they will have to be replaced when the time comes. First of all, the importance of iron is great. Only 1 gram of iron can be formed annually in the ground. However, when galvanizing is not carried out, the amount of lost iron comes out to frightening values. According to atmospheric conditions and the existence of the nature, it is necessary to preserve the iron. The methods used for this are too many. In order to prevent corrosion, the cathode protection can be provided by completely preventing the debris from external contact. The most suitable and commercial method that can make both of these factors together is hot dip galvanizing method. For example, when paint is applied to the material, the iron is completely chemically protected from external influences. But in the place where a small bi-pulse is generated, the rust layer begins to form rapidly and this causes the iron to rust and cause the paint to be overtaken. If we think that the galvanizing is going to happen if we give the example of galvanizing for this, the iron cation there will serve as zinc anion and the galvanizing anodic protection duty will sacrifice itself and prevent the formation of rust in the iron. Thus, the galvanized material provides excellent protection against corrosion even when it is affected by mechanical factors. Of course, if we think about the commercial size of this business, we will get an average of 200 tons when we think that it is 6-10 tons in a pole (132 Kv) even if 1 km or even 25 poles are planted. We can think of the kilometrics that find 100 kms or even thousands of miles of space where your electricity is going to go.

Ateş Refractory

Ates Refractory company, also known from the Ateş(which means Fire in Turkish) name, compares refractories with fire heat energy without damaging the two sides to make it more productive. Our company will offer the most suitable prices by supplying the materials to our customers; in place, on time and the best quality.

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