Uml Galvanization

7/31/2019 Uml Galvanization

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GALVANIZATION

Galvanization refers to any of several electrochemicalprocesses named after the Italian scientist Luigi Galvani. It

refers to an electro deposition process used to add a thin layer

of another metal to an item made of steel, in order to prevent

rusting. More recently, though the term has been broadened in

common usage to include applying a protective metallic coating

to an underlying piece of metal, using a process known as hot-dip galvanization.

Approximately, one third of the steel shipped by the

company/industry is coated on its surface by a metallic,

inorganic or organic coating. In this group the most widely

used coatings are zinc, zinc alloys or aluminum.

In hot dip galvanizing lines, which also have usual entryand exit groups, the strip moves first at constant speed say

150 m/sec through a cleaning section and a long,

horizontal, non-oxidizing pre heating furnace. The hot

strip, still protected by the inert furnace atmosphere in

along steel channel, enters the zinc bath at temperature ofabout 480 degree Celsius, supplying heat to the zinc bath

which is at about 440 degree Celsius. The liquid zinc is

contained in a refractory-lined, induction-heated vessel

called the zinc pot. When it contacts the strip surface, the

liquid zinc alloys with the iron and forms a strong


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metallurgical bonding. However, the iron zinc alloy is

brittle, so that the coating if too thick, will crack during

formation and keeping the alloy layer less than 15 % of the

total coating thickness. Excess liquid zinc is wiped off each

side of the strip by two gas knives, which have long, slotlike orifices through which high gas is blown. Coating

thickness is controlled by adjusting gas pressure and

location of knives.

Electrolyte galvanizing lines have similar entry and exitsections, but they deposit zinc in as many as 20 electrolytic

cells. Zinc cat ions present in the electrolyte are converted

by the current into regular zinc atoms, which deposit on

the work piece. The bath is supplied with zinc cat ions. The

electrolyte is an acidic sulphide of zinc sulphide or zinc

chloride with other bath additives to improve the quality

of the coating and the current efficiency. Coating thickness

is easier to control because of good relationship between

electric current and deposited zinc. The control

parameters of such a line are mainly the current density

between cathodes and work piece, the line voltage, the

chemical composition of the electrolyte, and base speed.

Electrolytic lines normally produce lower coatings weights

than do not dip lines, and they can also easily supply


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differential coatings on one sided coatings for specific

applications.

Many lines can deposit, zinc alloy coatings, such as zinc-

nickel or zinc-iron, and some lines are capable of

producing multilayered coatings, the goal being tooptimize a combination of specific requirements such as

corrosion resistance, durability. The processing speed of

electrolytic galvanizing lines can often reach 180 meters

per minute.

Electrolytic timings lines for the production of tin plate

are in principle, of similar design, except that all rolls are

smaller, the line speed is faster and differential electrolyte

and anodes are used. Electrolytic coatings lines also

coating lines also coat work piece with chromium and

other metal and alloys. Most of these lines have a shear

line installed at the end to produce work piece upon

request.

Many long products are also surface coated. Wires

are often hot dip galvanized in continuous multi-strand

lines. In addition, electrolytic coating of wire with all type

ofmetal is often done by hanging coils from currying c-

hooks.


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LE-4 FURNACE

SPECIFICATION

TOTAL LENGTH-22 M PRE-HEATING LENGTH-6.25 M VESTIBULE-15.75 M TOTAL WIDTH1.4M

TEMPERATURE SPECIFICATION {DEGREE

CENTIGRADE}

ZONE 1-1030 to 1050 {SLIGHT AIR RICH} ZONE 2-1010 to 1030 {SLIGHT AIR RICH} ZONE 3-970 to 990 {SLIHT GAS RICH} ZONE 4-P70 to 990 {SLIGHT GAS RICH}

There are four types of furnace:

1.LE-FOUR FURNACE2.D.S.W (DIRECT STEEL WORK) FURNACE3.F-44.F-3


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Finishing Products:

It may be classified into 3 types:

5.MS-16.MS-27.MS-3


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LE-4 FURNACE

Le-4 furnace is a furnace very popular for wire heat treatment

process in this furnace wires are treated in steps. The product

coming out of furnace is of very high quality and high strength.

PAY OFF:

It consists of five kinds of material

24 inch bag in

22/28 inch former DIM 1000 Rollers Separator

ROLLERS:

These are used to roll the wire to increase their straightness

and surface finish. There are many set of rollers for the wires.

There are two types of rollers

1ST TENSION ROLLER:

This is the first set of rollers for wire to pass. They bridge out

tension in wire and straighten it.


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HEAT TREATMENT PROCESS

Firstly, the wire is or the rod is made to go inside the furnace.

This is the first step to make a wire. The furnace has different

zones. One of the zones has a temperature of about 1000 degree

C to heat up the rod. And then the other zones have a

temperature of 500 degree C to suddenly cool up. This is called

head (Pb) bath. After it gets out of the furnace it is made to go

pass through the sand.

Thereafter, it is made to clean up by passing through the water

tank, this is made because to clean up the sand. After that it is

made to pass through acid, basically HCl, and then again it is

cleaned by water. It is water with phosphate because in wire

will, when it is passed through a die it will not create heat. So

to decrease heat, it is us ell this is called heat treatment process

to increase ductility.


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PICKLING

Originally, continuous wire pickling systems were open bath of

acid with mechanical devices (sinkers)

used to submerge the wires, later developments included

heating of the acid and addition of covers with fume extractors.

A subsequent improvement was the flood weir system in

which the acid is pumped from a reservoir tank to the

processing tray before overflowing back to the reservoir, thus

eliminating the need for sinkers and laminar. With the advent

of water seals in July 2, 1984 wire pickling systems became

known as fumeless.

One of the more recent developments in continuous wire

pickling systems is for the hydraulic jump type of wire

pickling apparatus. This design has permitted an increase in

the wire speeds but has the disadvantages of a relatively short

turbulent region in the wire speeds but has the disadvantages

of a relatively short turbulent region confined to only one acid

section. During pickling operation the acid (eq. HCL) becomes

chemically depleted thus necessitating the dumping of part ofthe tank so that fresh acid can be added. Since the hydraulic

jump system has only one acid section, a large volume of fluid

must be drained each time fresh acid is required to create

hydraulic jump. Another disadvantage is that large and

expensive acid pump is required to create a hydraulic jump.


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A PROJECT REPORT

ON

PICKLING, PATENTING AND

GALVANIZATION PROCESS

SR.MANAGER HRD:

ARVIND KUMAR

GUIDED BY: SUBMITTED BY:

K.N.MAHTO 1.MRINAL KAR(GYAN VIHAR UNIVERSITY, JAIPUR)

LETTER NO: - HRD/SUM/TRG/O61/12-13.

2. KUMAR SAURAV

(SRI CHANDRASEKHAREDRA

SARASWATI VISWA MAHAVIDYALAY)

LETTER NO: - HRD/SUM/TRG/321/12-13.


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[Low strength 2-12]

[High strength 12-20]

(26-32) (Temp. 70 +_ 5 C)

(100-115) gm/lit.(Temp 90 c)

HCl

PICKLING

RINSE WATER

BORAX

WIRE DRAWING

WATER RINSE

HCl

PHOSPHATE


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PREFACE

We take an opportunity to present this standard treatise

entitled as STUDY OF PATENTING, PICKELING AND

GALVANISING PROCESS at Usha Martin Ltd. RANCHI.

The objective of this for me is to learn the various

manufacturing processes of wire in industry, to understand the

team work during the working hours.

This project covers the background history of Usha MartinLtd., evolution of company, crossing the various hurdles with

serving the nation. In this project, I have covered the products

of Usha Martin Ltd with its application in various fields. This

project is all about obtaining of raw material for wire and rope

making to dispatch to various customers via various

manufacturing processes; viz-patenting, pickling, galvanizing,inspection after galvanizing and winding.

I have taken the help of various standard books. I also went

through some of the internet sites to get the right idea of

presenting this project.


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ACKNOWLEDGEMENTWe owe a sincere thanks to many people who helped and

supported me during this project. My heartiest thanks to Mr.

Arvind Kumar, Manager HRD, Usha Martin, for providing me

an opportunity to make this project and for his sincere

support.

We would also like to thank my institution and my

faculty members without whom this project would have been a

distant reality. I also extend my heartfelt thanks to my family

and well wishers.

1. Mrinal Kar

2. Kumar Saurav


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PATENTING

The special heat treatment given to a medium carbon, high

carbon and alloy steel wire rod is called patenting. The process

consists heating the material well above the austenitzing

temperature to ensure formation of homogenous austenite.

After soaking for sufficient time at this temperature, the steel

is quenched in a bath maintained at constant temperature. For

given steel, the quenching bath temperature is kept in the

vicinity of the nose of TTT curve. This results in

transformation of austenite to fine pearlite. Once the

transformation is complete the steel is cooled either in air or by

spraying water. In some cases, a small amount of upper bainite

has been observed. Lead bath or salt baths are commonly used

for quenching the steel. The process is mainly used for wires,

ropes and springs.

The higher the soaking is always above the austenitizing

temperature, the greater is the stress developed, making the

steel susceptible to distortion and quench cracks. This isparticularly dangerous for high carbon steels. On the contrary,

use of too low temperature is again not desirable as it imparts

poor mechanical properties, especially ductility, as measured

by percentage elongation and percentage reduction in area.

Patenting heat treatment results in a homogenous and fine


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pearlitic structure; such a structure is capable of heavier

drafting during wire drawing than is possible with common

heat treatment process. Since low carbon steels can be drawn

heavily in an annealed condition, patenting heat treatment is

not employed or such steel.


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MANUFACTURING PROCESS OF ROPE


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REFERENCES

1. www.google.com

2.www.wikipedia.org

3. www.ushamartin.com
http://www.wikipedia.org/http://www.wikipedia.org/http://www.wikipedia.org/


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MANUFACTURING PROCESS OF WIRE

STRAND


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CONTENT

1. GROUP PROFILE

2. LE-4 FURNACE3. HEAT TREATMENT

4. PICKLING

5. PATENTING

6. GALVENIZATION7. CONCLUSION

8. REFRENCES


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LE-4 FURNACE: FLOW CHART

PAY OFF

FURNACE

LEAD BATHSAND BATH

WATER BATH

Auto spoke

PHOSPHATE BATH FLUX BATH

WATER BATH DRYER FOR L.C.G.

BORAX BATH ZINC BATH

DRYER FOR PWLC CHARCOAL WIPING

LIME BATH

ACID BATH

ACID 1

ACID 2

TAKE UP

WATER BATH

BORAX

BATH

PAY OFF

FURNACE

LEAD BATH


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CONCLUSION

UML is the 2nd largest wire and rope manufacturer in the

world and has the largest variety in South East Asia. It is multi

product, diversified engineering conglomerate with 10

production units in India, 1 in Thailand, 1 in UK and 1 in

Dubai. It is saving valuable foreign exchange by exporting its

product to 42 countries like USA, Africa and Middle East,

conforming to the strictest product quality standards. It is a

constant supplier of wire and aired rope. With the modern

concepts like TPM, value engineering, customer satisfaction

and human resource development, it is trying to reach

unparalleled heights. UML provides revenue to the

government and also provides employment to lots of people.

UML is serving through a leading daily Prabhat Khabar,

Krishi Gram Vikas Kendra, Usha Martin Technical Institute.

Uml Galvanization

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