Malaysia Key Economic

Indicators
Source: Bank Negara Malaysia

HES5195_09S2_W02_GI_2
 Scope

1. Fundamental information about STEEL

¾ Types Of Steel Making Process
2. Corrosion And Prevention
¾ Why Corrosion Occur
¾ How to prevent Corrosion
3. Types Of Galvanising
¾ Continuous Galvanising Line
¾ General Galvanising

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 Iron Coking Limeston ZIN
Ore Coal e C

1. Steel Making Process

Blast Basic Oxygen Continuous

Furnace Furnace Casting

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Steel Making Process

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 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:

3Fe2O3 + CO = CO2 + 3 Fe3O4 Begin at 450°C

Fe3O4 + CO = CO2 + 3FeO Begin at

600°C

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.

CaCO3 = CaO + CO2

At about 875°C

FeS + CaO + C = CaS + FeO

+ CO

€ CaS becomes part of

slag and will be
removed at the end of
the process.
HES5195_09S2_W02_GI_8
 Basic Oxygen Furnace (BOF)

€ Steel making furnace in which convert iron

pig and steel scrap into steel due to
oxidizing action.

€ Most powerful and effective steel making

method in this century.

€ Lime might be used for sulphur

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.
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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.

€ 3 basic types of continuous caster is:

y Vertical Caster
y Vertical with Bending
y Curve type

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 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.

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Continuous Casting

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Steel Making Process

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 2. Corrosion & Prevention

Continuous Galvanising
Corrosio
Line
n
Zinc Ingot

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 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.

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 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

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Corrosion And Prevention

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 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

Continuous Galvanising General

Line Galvanising
Zinc Ingot

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

€ The products that are galvanised by 99% Zn are called

Galvanised Iron (GI)

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 Hot-Dipped Galvanising (HDG)

Non Oxidizing Furnace Continuous Galvanizing

Line (NOF-CGL)

HES5195_09S2_W02_GI_27
Hot-Dipped Galvanising (HDG)

General Hot-Dipped Galvanising

HES5195_09S2_W02_GI_28
 Electro-Galvanising (EG)

€ Electro-galvanising involved in immersion

of degreased and pickled steel into a zinc
salt solution and connected as a cathode to
a direct current source. Rod or balls of
pure zinc are connected as anodes. Zinc
from the electrolyte is deposited on the
steel surface.
€ The thickness vary from 5 to 25 μm with
very even coating and silvery, metallic
sheen.

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

€ Degreased steel objects are placed in a

drum, together with glass balls, are first
tumbled in an acidic cleaning agent and
then in a copper plating agent. The objects
are then tumbled with zinc powder and
certain activating chemical.
€ Zinc is usually deposited in layers with
thickness between 12 and 15 μm, although
thicker layers of about 75 μm are said to be
obtainable.
€ The coating is uniform with matt surface.

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.

9 Excellent corrosion resistance in most

environments.
9 Ability to form dense, adherent corrosion
product films.
9 Zinc has a slower rate of corrosion (10 to 100
times slower) below that of ferrous metal.
9 Zinc has the ability to cathodically protect the
base metal. (Galvanic action). Zinc being anodic
to iron and steel, will preferentially corrode and
protect the iron and steel against rusting when
the coating is damaged.
HES5195_09S2_W02_GI_35
 WHY USE ZINC?
9 Good applicability, relative economics and
expected service life.
9 Durability – protection at all corners, edges
and threads, hardness, density and thickness.
9 Zinc is an environmental friendly metal. Zinc
is a natural element that is essential to all
forms of life including humans, animals, plants
and micro-organisms. While small quantities
of zinc will wash off from coatings exposed to
outdoor environments, the zinc is usually not
bio-available and has little or no impact on the
surrounding ecosystem.
9 Zinc is fully recyclable.

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 Plating Electrolysis ASTM B 633 0.2 to 1.0 mils²

mils² Interior or Exterior. Fasteners and
hardware items.

Mechanical Peening ASTM B 695 0.2 to 4.3 mils²

mils² Interior or Exterior. Fasteners and
Plating hardware items.

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

Coated Sheet ASTM Standard/ Comments

Common Name JIS

Hot-dip galvanized A 653/A 653M Zinc-coated sheet

JIS G3302
G3302

Hot-dip galvannealed A 653/A 653M Zinc-iron alloy-coated sheet

JIS G3302
G3302

Electrogalvanized A 591/A 591M Thin electroplated zinc-coated sheet

JIS G3313
G3313

Electrogalvanized A 879/A 879M Heavier electroplated zinc-coated sheet

Galvalume A 792/A 792M 55% aluminum/ 45% zinc alloy-coated sheet

Galfan A 875/A 792M 95% zinc/ 5% aluminum alloy-coated sheet

JIS G3317
G3317

Aluminized A 463/A 463M 2 types o aluminum coating

JIS G3314
G3314 * pure aluminum-
aluminum-coated sheet
* aluminum/ 5%
5% - 11% silicon alloy-
alloy-coated sheet

Teme A 308/A 308M Lead/ tin alloy-coated sheet

Electroplated Zinc/Nickel A 918 Zinc/ 9-16% nickel alloy electroplated coated sheet
HES5195_09S2_W02_GI_48