Documente Academic
Documente Profesional
Documente Cultură
Indicators
Source: Bank Negara Malaysia
HES5195_09S2_W02_GI_2
Scope
HES5195_09S2_W02_GI_3
Iron Coking Limeston ZIN
Ore Coal e C
HES5195_09S2_W02_GI_4
Steel Making Process
HES5195_09S2_W02_GI_5
Blast Furnace
Purpose:
y Chemically reduce or physically convert iron oxide
into liquid iron (Hot Iron).
Operation:
y Iron ore, coke and limestone are dumped from top of
the furnace.
y Preheated air blow into furnace from bottom.
y Required 6 to 8 hours to melt the raw materials.
y Continuously work for 4 to 10 days with only short
stops to perform planned maintenance.
y Input raw materials can be in the form of raw ore,
pellets or sinter.
HES5195_09S2_W02_GI_6
Blast Furnace
Reactions happen inside blast furnace can
be represented by the formulas as below:
FeO + CO = CO2 + Fe
or Begin at 700°C
FeO + C = CO + Fe
HES5195_09S2_W02_GI_7
Blast Furnace
Limestone was added
into the process to
remove the sulphur
from the iron.
HES5195_09S2_W02_GI_9
Basic Oxygen Furnace (BOF)
Operation:
y Charging steel scrap (25 – 30% of total weight).
y Pouring iron pig from blast furnace.
y Charging fluxes.
y Lime used for sulphur and phosphorus removal.
y Start oxygen blowing. Duration of blowing is about
20min.
y Sampling. Temperature measurements and taking
samples for chemical analysis are made through the
upper cone in tilted position of furnace.
y Tapping.
y De-slugging.
HES5195_09S2_W02_GI_10
Basic Oxygen Furnace (BOF)
HES5195_09S2_W02_GI_11
Continuous Casting
Process whereby molten steel is
solidified into a “semi-finish” billet, bloom
or slab.
HES5195_09S2_W02_GI_12
Continuous Casting
Operation:
y Tundish, located above the mold to feed liquid
steel to the mold at a regular rate.
y Primary cooling zone which to generate a
solidified outer shell.
y Secondary cooling zone which provide further
solidified and strand.
y Unbending and straightening section (except
vertical caster).
y Shear the solidified strand into pieces.
HES5195_09S2_W02_GI_13
Continuous Casting
HES5195_09S2_W02_GI_14
Steel Making Process
HES5195_09S2_W02_GI_15
2. Corrosion & Prevention
Continuous Galvanising
Corrosio
Line
n
Zinc Ingot
HES5195_09S2_W02_GI_16
What is Corrosion?
Corrosion can be defined as the
destruction or deterioration of a material
or its properties by reaction with the
environment.
Corrosion can occur through chemical or
electrochemical reaction and is usually
an interfacial process between a
material and its environment.
Broadly speaking, all metals, with the
possible exception of precious metals,
are corroded and destroyed with time.
HES5195_09S2_W02_GI_17
What is Corrosion?
For steel to corrode or rust in normal
environment, it must have access to
both oxygen and water.
2H2O + O2 +4e- → 4(OH)-
2Fe → 2Fe2+ + 4e-
Fe2+ + 2(OH)- → Fe(OH)2 Ferrous
Hydroxide
This subsequently oxidizes to rust Fe(OH)3
HES5195_09S2_W02_GI_18
Corrosion And Prevention
HES5195_09S2_W02_GI_19
Corrosion Prevention
The rusting process in steel can be
impeded by any of the following:
y By alloying the steel with elements such as
chromium, nickel, molybdenum, etc. For
ordinary steel structures, however, these steels
are too expensive.
y Changing of the corrosive environment by
reducing the access of water and oxygen
through techniques such as dehumidification,
inert atmospheric blankets, etc. in totally
immersed aqueous environments inhibitors may
be added to reduce the aggressively of the
solution.
HES5195_09S2_W02_GI_20
Corrosion Prevention
y Cathodic protection through the utilization of
sacrificial anodes or impressed direct current.
The method using sacrificial anodes can be said
to be a form of controlled galvanic corrosion,
since the metals are arranged so that one of
them is allowed to corrode while the other is
protected. Cathodic protection can only be used
in the presence of an electrolyte, such as water
or moist soil. The method is used for the
protection of ships, small boats, quays, offshore
oil platforms, tanks, pipelines, etc..
HES5195_09S2_W02_GI_21
Corrosion Prevention
y Coating with inorganic or organic material, for
the purpose of excluding water and oxygen from
the steel surface. This is the most widely used
method of protection against corrosion. The
inorganic materials can be metals and vitreous
enamels, The organic materials can be paints,
bitumen products or plastics.
HES5195_09S2_W02_GI_22
Corrosion Prevention
Metal coating of steel will provide
protection against corrosion, give wear
resistance, and sometimes a decorative
effect.
Only a few of the metals that can be
deposited on steel are cost-effective and
cathodic to steel. In fact, only zinc and
aluminum can really be considered,
Cadmium is used to some extent but
environmental concerns limit its use.
Zinc is one of the least expensive
nonferrous metal
HES5195_09S2_W02_GI_23
3. Types of Galvanising
HES5195_09S2_W02_GI_24
What is Galvanizing?
Galvanising is a process of coating a protective
layer of zinc on steel. It is one type of metal
coating with cathodic protection.
Galvanising methods:
1. Hot-Dipped Galvanizing.
2. Electro Galvanizing.
3. Zinc Metal Spraying.
• 4. Sheradizing.
• 5. Mechanical Plating.
• 6. Coating with Zinc-Rich Paint/Epoxy
HES5195_09S2_W02_GI_25
Hot-Dipped Galvanising (HDG)
Hot-dipped galvanising involved in immersion of
degreased and pickled steel into molten zinc at
temperature of around 460°C.
There are two types of hot-dipped galvanising:
y General Hot-Dipped Galvanising
○ For various steel components
y Hot-Dipped Galvanising for Sheet Metal or
y Continuous Galvanising Line for Steel Sheet
○ For steel sheet metal normally in coil form
HES5195_09S2_W02_GI_26
Hot-Dipped Galvanising (HDG)
HES5195_09S2_W02_GI_27
Hot-Dipped Galvanising (HDG)
HES5195_09S2_W02_GI_29
Zinc Metal Spraying
The steel is cleaned by mean of abraive mating.
Zinc is fed into the spray gun in the form og wire or
powder and melted by a gas flame or electric arc.
The molten droplets are then sprayed onto the
steel surface with the aid of compressed air.
The zinc layer can exhibit porosiy and the surface
may be coarse. The thickness of the coating can
be varied from 30 to 300 μm. Adhesion to the
steel surface is purely mechanical.
HES5195_09S2_W02_GI_30
Sheradizing
Ths steel cleaned through pickling, are
packed together in a drum with zinc
powder and sand. The drum is rotated and
heated to just below the melting
temperature of zinc, iron and zinc react
with each other to form an iron/zinc alloy
on the steel surfaces.
Sharadizing give relative thin coating about
15 to 40 μm with dark grey surface.
The coating have good adhesion properties
and a very uniform thickness. This method
has about the same range of application as
fro electro-galvanising.
HES5195_09S2_W02_GI_31
Mechanical Plating
HES5195_09S2_W02_GI_32
Coating with Zinc-Rich
Paint/Epoxy
Steel components are cleaned by means of
abrasive blasting then zinc-rich paint consists of
fine grained zinc powder in an organic bonding
agent.
The zinc content in the dry paint film should be
ideally 92% by mass, which corresponds to 62% in
volume. The paint is applied by brush or spray
gun.
HES5195_09S2_W02_GI_33
Comparison of Coating
Comparison between the properties of
different zinc coatings:
HES5195_09S2_W02_GI_34
WHY USE ZINC?
Zinc has a number of characteristic that make it
well suited for use as a coating for protecting
iron and steel products from corrosion.
HES5195_09S2_W02_GI_36
WHY USE ZINC?
Arrangement of Metal in Galvanic Series
HES5195_09S2_W02_GI_37
Properties of Zinc
HES5195_09S2_W02_GI_38
Properties of Zinc
HES5195_09S2_W02_GI_39
Properties of Al
HES5195_09S2_W02_GI_40
Galvanized VS Aluzinc
Aluzinc contain high level of Al which is
not good for soldering. Zinc coating is
good for soldering. Joining by soldering
is possible for galvanized.
Sheets with Aluzinc coating is not
suitable for wet concrete.
Aluzinc cannot have direct contact with
lead, copper, graphite, green wood, wet
or treated wood as all these cause
galvanic corrosion to the Aluzinc sheet.
HES5195_09S2_W02_GI_41
Galvanized VS Aluzinc
Aluzinc cannot be used for high build
system such as Plastisol system. With
Plastisol system the corrosion creeps
under the film causing peeling.
Aluzinc coating is less dense than
galvanised as aluminum is less dense
than zinc thus giving a much less dense
protection. Increasing aluminum content
and reducing zinc reduces the density of
the coating.
HES5195_09S2_W02_GI_42
Galvanized VS Aluzinc
In coating Aluzinc because of the high
aluminum content the bath requires a
much higher temperature thus affecting
the quality of the steel sheet.
In Aluzinc because of the high aluminum
content it can be said that this alloy
behaves like aluminum coating with zinc
instead otherwise.
The high percentage of aluminum in
Aluzinc coating makes the product more
expensive because the price of
aluminum is much higher.
HES5195_09S2_W02_GI_43
Galvanized VS Aluzinc
The cost of producing Aluzinc coating is
much higher due to the higher alloy cost
and the need for higher bath
temperature.
The only good thing about Aluzinc
coating is its outstanding corrosion
resistant direct and elevated
temperature resistant properties.
HES5195_09S2_W02_GI_44
Relative performance
5=best
1= worst
PERFORMANCE AREA GALVANIZED ZINCALUME
Formability 3 3
Corrosion resistance 3 5
(bare)
Sacrificial protection 5 3
Corrosion resistance 3 3
(formed)
Paint adhesion 4 4
Weldability 4 2
HES5195_09S2_W02_GI_45
Service Life vs Thickness of Zinc
11 21 32 43 54 65 75 86 97 108 118 129
Thickness of Zinc in Micrometers
80
l
70 ra
Ru
60
e
M arin
l
ica
Service Life, Years
o p
Tr e
50
M arin
te
p era n
Tem b u r ba
40 Su
l
d u stria
ly I n
d erate
30 Mo
20
10
0
Oz. of Zinc/Sq. Ft. of Surface
.25 .50 .75 1.00 1.25 1.50 1.75 2.00 2.25 2.50 2.75 3.00
Thickness of Zinc in Mills
0.4 0.8 1.3 1.7 2.1 2.6 3.0 3.4 3.8 4.2 4.7 5.1
* Service Life is defined as the time to 5% rusting of the steel surface HES5195_09S2_W02_GI_46
ZINC COATINGS
Method Process Specification Coating Thickness Application
Electro-
Electro- Electrolysis ASTM A 879 Up to 0.28 mils Interior. Appliance panels, studs,
galvanizing acoustical ceiling members.
Zinc Hot Zinc Spray AWS C2.2 3.3 to 8.3 mils Interior or Exterior. Items that cannot
Spraying be galvanized because of size or
(Metallizing) because on-
on-site coating application is
Metallizing)
needed.
Continuous Hot-
Hot-Dip ASTM A 653/ Up to 4.0 mils¹
mils¹ Interior or Exterior. Roofing, gutters,
Sheet JIS G3302 culverts, automobile bodies.
Galvanizing
Hot-Dip
Batch Hot- Hot-
Hot-Dip ASTM A 123 1.4 to 3.9 mils³
mils³ Interior or Exterior. Nearly all shapes
Galvanizing ASTM A 153 and sizes ranging from nails, nuts and
ASTM A 767 bolts to large structural assemblies,
including rebar.
CSA G164
Zinc Spray SSPC-
SSPC-PS Guide 0.6 to 5.0 mils/coat Interior or Exterior. Items that cannot
Painting Roller 12.00, 22.00 be galvanized because of size or
Brush SSPC- because on-
on-site coating application is
SSPC-PS
needed. Large structural assemblies.
Paint 20 Aesthetic requirements.
SSPC-
SSPC-PS 12.01
Standards for Coatings
Electroplated Zinc/Nickel A 918 Zinc/ 9-16% nickel alloy electroplated coated sheet
HES5195_09S2_W02_GI_48