Utkarsh India Limited

Operation process of Structure Galvanizing

Step 1. Raw Material Received

Step 2. Acid Base Degreaser
Step 3. Acid Pickling
 Scrubber System
 Storage of Waste Acid
Step 4. Rinsing Water
Step 5. Flux Solution, Flux Filtration and Regeneration
Step 6. Drying Process
Step 7. Zinc Bath
Step 8. Quenching process
Step 9. Passivation Process
Step 10. De-jigging and hanger unloading
Step 11. Inspection , marking ,Packing

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1. Scope

 This standard Covers the requirement for zinc coating applied by hot dip
galvanizing on mild steel .

2. Procedure

A. Raw Material Received And jigging area

a) At first check Route Card

b) Check Identification No.
c) Check Black materials must be free from rolling defect.
d) Check Black materials must be free from Burr, Paint, Grease,
etc.
e) Check receiving section, weight, thickness, length.
f) Check drainage holes and lifting hole.
g) Check receiving quantity.
B. Acid Base Degreaser

a) Tank size – (12500 X 1200 X 1250) mm

b) Chemical volume -13000 ltr.
c) Chemical preparation- Added 75% water (v/v) , 20%
Degreasing chemical(v/v) and 5 % Hydrochloric acid (v/v)
d) Handling the chemicals with proper safety
e) Maintain the Specific Gravity of chemical 1.10 to 1.25

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f) Maintain temperature is ambient
g) Material Immersion time 7 to 10 min.
h) Degreasing solution parameter checking on regular basis.
i) Degreasing chemical filtering time after 3000 MT production

C. Acid Pickling

a) Raw Hydrochloric Acid 32 %(w/w) Received and storing in

main tank (cap-18 kl)
b) Tank size – (12500 X 1200 X 1250) mm
c) Chemical volume -13000 ltr.
d) Chemical preparation- Added 40 % water (v/v) , 60%
Hydrochloric Acid (v/v) , 3.5 % Fumes suppressant (v/v) or
0.02 % Inhibitor (v/v)
e) Handling the chemicals with proper safety
f) Maintain the Specific Gravity of chemical 1.08 to 1.26
g) Maintain the Iron content of chemical 0 to 120 gm/ltr
h) Maintain temperature is ambient
i) Material Immersion time 20 to 30 min
j) Pickling solution parameter checking on regular basis.

k) Check the assay and Sp. Gravity of raw hydrochloric acid on lot
basis.
l) Minimum production 450 MT. maximum production 550 MT.
m) Acid Discard in 5 % and transfer to ETP

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 Acid fumes Scrubber System

a) Sucks acid fumes from working pickling tanks

b) Dissolves acid fumes in continuous water shower
c) Acidic water so made used back in pickling tanks or through ETP.
d) Scrubber must be running 24 hrs. for protect environment and
health

 Storage of Waste Acid

a) Tank size – (12500 X 1200 X 1250) mm

b) Chemical volume -18750 ltr.
c) Chemical – waste Hydrochloric acid
d) Handling the chemicals with proper safety
e) Specific Gravity of chemical > 1.26
f) Strength of chemical - <5 % (v/v)
g) Maintain the Iron content of chemical > 120 gm/ltr
h) Maintain temperature is ambient
i) Material Immersion time not in used.
j) Hazardous in nature
k) Acid Discard and transfer to ETP

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D. Rinsing Water
Water rinsing is in two tanks
A. Rinsing water Tank 1
B. Rinsing water Tank 2
a. Rinsing Water Tank1
a) Tank size – (12500 X 1200 X 1250) mm
b) Chemical volume -13000 ltr.
c) Chemical preparation- 100 % R.O water or Raw water
d) Rinsing water must be filled from bottom portion and reject
water must be drain by overflow
e) Maintain the pH of water 3 to 5
f) Maintain temperature is ambient
g) Material Immersion time 1 to 2 min
h) Rinse water drain in pH below 3 and transfer to ETP
b. Rising Water Tank 2
a) Tank size – (12500 X 1200 X 1250) mm
b) Chemical volume -13000 ltr.
c) Chemical preparation- 100 % R.O water or Raw water
d) Rinsing water must be filled from bottom portion and reject
water must be drain by overflow
e) Maintain the pH of water 5 to 6
f) Maintain temperature is ambient
g) Material Immersion time 1 to 2 min
h) Rinse water drain in pH below 3 and transfer to ETP

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E. Flux Solution

a) Tank size – (12500 X 1200 X 1250) mm

b) Chemical volume -13000 ltr.
c) Chemical preparation- ZnCl2(45%) , NH4Cl (55%) salt in D.M
water and 0.05 % Glycerin and 0.05 % Glycerin
d) Handling the chemicals with proper safety
e) Maintain the Specific Gravity of chemical 1.12 to 1.25
f) Maintain the Iron content of chemical 10 gm/ltr (maximum)
g) Maintain temperature is 50 to 80 OC through steam or heater
h) Material Immersion time 3 to 5 min
i) Maintain pH is 4 to 5
j) Flux parameter checking on regular basis.
k) Check the assay of zinc chloride and ammonium chloride on lot
basis
l) Flux must be filtered after 600 to 700 MT. productions.

 Flux Filtration And Regeneration

a) Pump out flux solution to another working Tank (size – 12500 X

1200 X 1250) mm
b) Chemical volume -13000 ltr.
c) Addition of liquid ammonia about 0.3 % to neutralize.
d) Precipitate Iron from the flux Solution as Ferrous hydroxide.
e) Then Add Hydrogen Peroxide 0.30 % to oxidize from ferrous to
ferric.
f) Filter Press separates Ferric Hydroxide.
g) Transfer sludge to sludge storage tank .

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F. Drying Process

a) After fluxing Material drying on hot Plate with Hot blowing

air.
b) Maintain temperature is 100 to 150 OC
c) Keeping Time 30 min (maximum)

G. Zinc Bath

a) Bath size – (12300 L X 1100 W X 1250 D) mm

b) Capacity -117 MT. Molten Zinc.
c) Maintaining Bath composition with 100mm Lead in the bottom,
Molten Zinc and trace amount of aluminum.
d) Maintain temperature is 445 to 460 OC (as per thickness and
volume of material)
e) Handling hot material with proper safety.
f) Material Dipping time depend on material thickness and volume.
g) Check the assay of zinc ingot , lead-zinc alloy and Aluminum-
zinc alloy on lot basis
h) Zinc bath Sample collect and testing of chemical composition
on weekly basis .
i) Drossing after 1000 MT of steel galvanizing

H. Quenching process

a) Tank size – (12500 X 1200 X 1250) mm

b) Chemical volume -13000 ltr.
c) Chemical preparation- 100 % D.M water

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d) Quenching water must be filled through bottom portion and
excess overflowing water transfer to cooling tower.
e) Maintain temperature is up to 60oC by using of cooling
tower.
f) Material Immersion time 2 to 5 min (as per volume of
material) to cool down the materials
g) Tank must be cleaned on weekly basis.
h) Maintain TDS of Quenching water up to 500 ppm
(maximum) to protect the material from white rust, look ,pill
up of the zinc coating etc.

I. Passivation Process

Two type of passivation tank used in process

A. Passivation Tank 1
B. Passivation Tank 2
A. Passivation Tank 1
a) Tank size – (12500 X 1200 X 1250) mm
b) Chemical volume -13000 ltr.
c) Chemical preparation- Add 1 to 2 % Passivation solution
in D.M water
d) Maintain temperature is up to 30 to 50oC
e) Material Immersion time 1 to 2 min (as per volume of
material)
f) Maintain pH is 3 to 5
g) Tank must be cleaned on monthly basis.
h) Material used TWR, CORE, etc.
B. Passivation Tank 2
a) Tank size – (12500 X 1200 X 1250) mm
b) Chemical volume -13000 ltr.

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c) Chemical preparation- Add 1.5 to 2 % Passivation
solution in D.M water
d) Maintain temperature is up to 30 to 50oC
e) Material Immersion time 1 to 2 min (as per volume of
material)
f) Maintain pH is 5 to 7
g) Tank must be cleaned on monthly basis.
h) Material used Lighting mast, lighting post and crash
barrier etc. .
i) Passivation solution parameter checking on regular basis.
j) Check the assay or Sp. Gravity pH of raw passivator
solution on lot basis

J. De-jigging and hanger unloading

a) Material is unloaded from hanger

b) Material are drying properly
c) Unwanted zinc lumps, sharp edge of zinc are removed from
the material

K. Inspection , marking and Packing

a) Plating thickness measurement and roughness, pill up, black

spot, oxide check are carried out.
b) Necessary marking is done and materials are packed for
dispatch.
c) In case of NC , the work is returned to step-3
d) Mechanical, chemical and galvanizing test is carried out after
complete of process. As per BIS standard.
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Uses Chemical and Metals in Galvanizing

1. Furnace Oil
2. Zinc ingot
3. Lead
4. Zinc alloy
5. Nickel
6. Degreaser
7. Hydrochloride Acid
8. Raw Water
9. D.M water
10. Acid inhibitor
11. Ammonium Chloride
12. Zinc Chloride
13. Liq. Ammonia
14. Glycerin
15. Hydrogen per oxide
16. Potassium permanganate
17. Passivator solution

By product in galvanizing

1. Zinc dross
2. Zinc ash

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