project hzl 2

ACKNOWEDGEMENT

The present study would not have been the light of the day without the due guidance and co-operation of HZL employees.

This project involves valuable contribution from some person. I wish to express my appreciation gratitude to every direct or indirect co-operation and assistance expanded to me, by different individual and officials of respective department of HZL.

This assistance was offered to me in different forms like dissemination of information in the form of broachers, pamphlet etc. provided which was helpful in completing the project report.

I shall always be indebted ZINC SMELTER, DEBARI, UDAIPUR for giving me an opportunity to undergo this summer training in such a prestigious and professional organization and also for their immense contribution towards execution and completion of the project.

As the outset I humble acknowledge the kind grace of the management of HZL for highly illuminating summer placement training.

I am thankful to Mr. P.K Jain for their guidance and gracious support in accomplishing this summer training successfully.

I would also like to present my heartfelt thanks to Mr. S.C. Sharma (Sale Manager) for their precious guidance, tolerance and understanding. I am really grateful to sir for the time they have spared for me during the course of my tenure in HZL, Debari.

Last but not the least I would like to thank all the employees of HZL and fellow summer trainees for their co-operation extended.

Date:- Neeraj Chaudhary

Place:- UDAIPUR

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Preface

We have just stepped in 21st century. In last century, India was developing country keeping pace with the rest of the world.

The mining industry has also played a vital role in development of the country, since independence the mining industry contributed a lot in making a fast development of the country. Keeping in view Zinc Smelter, Debari a giant company mainly involved in mining of Zinc, sulphuric acid, cadmium, lead, silver offers the opportunity to study, “ The Marketing Scenario of Zinc”.

Zinc and lead are the 23 and 34 most abundant elements on the earth crust among the oldest metal used by men in alloys and in metals. In terms of tonnage used, these are the fourth and most widely consumed industrial metals today after iron, aluminum and copper, sulphate and galena source of most of the world’s suppliers of these metals generally co-occur in association with minerals of sodium, silver, copper.

Zinc and lead are resources known to be hosted by at least six geological environment but most of the major deposits occur strata bound massive, mixed sulphide ores in metamorphic rocks and irregular breccias replacement in carbonate rocks. The primary producers of lead ore are US and ex-USSR and the primary producers of zinc ore are Canada and ex-USSR.

India has the pride of having the oldest known deposits of zinc ore at Zawar Mines. Zinc metals also used to be extracted through a crude Pyro metallurgical process in ancient times. Recognizing this zinc extraction district as the oldest in the world. American society of metals declared it as an INTERNATIONAL HISTRORICAL LANDMARK by placing at Zawar in Rajasthan state in 2nd of February 1989.

The industrial upswing that took place in the country during 60’s assured in a new era of zinc metal extraction from ores. It was during this decade that government of India, realized the strategic importance of zinc and lead metals incorporated HZL. The company has over the years, shriven hard to be bridge the gap between indigenous zinc production and the national demand.

Relationship of man with metals dates of the evolution of man himself. Common man generally associates the world metal only to such material that are made of gold, silver, platinum and copper and are unaware that most articles that he is using in day today life have a direct or indirect association of metal “Zinc” predominately zinc metal is known due to its unique property of corrosion resistance, which lands its uses for galvanizing. Today there is hardly any industrial sector of common product that has except the influents of zinc in some from or the other. Zinc is one of the essential non-ferrous metals required in the industrial economy and is fourth order of consumption amongst the major metals after iron, aluminum and copper.

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INTRODUCTION

The topic of my study is to “Analyze The Marketing Scenario of Zinc”. The company’s main objective to conduct this study is to find out whether company should increase its production capacity.

Under this topic I did the following analysis:

1) Actual production with installed capacity of company.2) Different uses of Zinc in different industry.3) Various data relating production and consumption of Zinc.4) Customer list of Debari Zinc Smelter.5) Conclusion and suggestion regarding.6) SWOT Analysis of the company.

SCOPE:

The scope of the present research work was to collect data or information from HZL, Debari.

In 2008, the consumption of zinc was about 10774000 tons which is expected to grow at 9% - 11.7% MT. The global zinc market to grow by 5% primarily on back of growth in emerging market such as china and India. Zinc consumption in India is expected to grow at 8% - 10%p.a from current demand of 4,20,000 MT driven by growth in steel, infrastructure and automobile industry.

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ZINC PROPERTIES

30 ZINC

Zn

periodic table - Extended Periodic Table

General

Name, Symbol, Numberzinc, Zn, 30

Chemical series transition metalsGroup, Period, Block 12, 4, dAppearance bluish pale grayAtomic mass 65.409(4) g/molElectron configuration [Ar] 3d10 4s2Electrons per shell 2, 8, 18, 2

Physical Properties

Phasesolid

Density (near r.t.) 7.14 g·cm−3Liquid density at m.p. 6.57 g·cm−3

Melting point692.68 K(419.53 °C, 787.15 °F)

Boiling point1180 K(907 °C, 1665 °F)

Heat of fusion 7.32 kJ·mol−1Heat of vaporization 123.6 kJ·mol−1Heat capacity (25 °C) 25.390 J·mol−1·K−1

Vapor Pressure

P/Pa 1 10 100 1 k 10 k 100 k

at T/K 610 670 750 852 990 (1185)

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Atomic properties

Crystal structurehexagonal

Oxidation states2(amphoteric oxide)

Electronegativity 1.65 (Pauling scale)Ionization energies(more)

1st: 906.4 kJ·mol−12nd: 1733.3 kJ·mol−13rd: 3833 kJ·mol−1

Atomic radius 135 pmAtomic radius (calc.) 142 pmCovalent radius 131 pmVan der Waals radius 139 pm

Miscellaneous

Magnetic orderingdiamagnetic

Electrical resistivity (20 °C) 59.0 nΩ·mThermal conductivity (300 K) 116 W·m−1·K−1Thermal expansion (25 °C) 30.2 µm·m−1·K−1Speed of sound (thin rod) (r.t.) (rolled) 3850 m·s−1Young's modulus 108 GPaShear modulus 43 GPaBulk modulus 70 GPaPoisson ratio 0.25Mohs hardness 2.5Brinell hardness 412 MPaCAS registry number 7440-66-6

Notable Isotopes of Zinc

iso NA half-life DM DE (MeV) DP

64Zn 48.6% Zn is stable with 34 neutrons

65Zn syn 244.26 dε - 65Cu

γ 1.1155 -




69Zn syn 56.4 min β− 0.906 69Ga


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http://www.iza.com/wiki/1_E-10_m


http://www.iza.com/wiki/Van_der_Waals_radius


http://www.iza.com/wiki/Covalent_radius

THE HISTORY OF ZINC

Centuries before zinc was discovered in the metallic form, its ores were used for making brass and zinc compounds, its ores were used for healing wounds and sore eyes. It is believed that the Romans first made brass in the time of Augustus (20 B.C. – 14 A.D.). In the 13th century Marco Polo described the manufacture of zinc oxide in Persia.

By 1374, zinc was recognized in India as a new metal – the 8th metal known to man at that time. At Zawar, India, both zinc metal and zinc oxide were produced from the 12th to the 16th century. Zinc metal was used to make brass and zinc oxide served medical purposes.

From India, zinc manufacturing moved to China in the 17th century where it developed as an industry to supply the needs of the brass industry.

Zinc was recognized in Europe as a separate metal in the 16th century when Agricola (1490 – 1555) observed that a metal called “zincum” was produced in Slesia and Paracelsus (1493 – 1541) stated clearly that “zincum” was a new metal. In 1743, the first European zinc smelter was established in Bristol in the United Kingdom using a vertical retort procedure. A major technological improvement was achieved with the development of the horizontal retort process in Germany which led to the erection of smelting works in Slesia, Liege, Belgium and Aachen, the Rhineland and the Ruhr areas in Germany. In 1836 hot-dip galvanizing, the oldest anti-corrosion process, was introduced in France.

Zinc production in the United States started in 1850.

For about 500 years zinc was produced from its oxide ores before the more abundant sulfides became the major source of supply. On the technological side there was a drastic change in 1916 when the electrolytic process was introduced on a large scale replacing the hydrometallurgical process as the dominating production method.

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ZINC - NATURAL OCCURRENCE

Zinc is a natural component of the earth’s crust and an inherent part of our environment. Zinc is present not only in rock and soil, but also in air, water and the biosphere. Plants, animals and humans contain zinc.

Minerals and metals are mostly obtained from the earth’s crust. The average natural level of zinc in the earth’s crust is 70 mg/kg (dry weight), ranging between 10 and 300 mg/kg (Malle 1992).

In some areas, zinc has been concentrated to much higher levels by natural geological and geochemical processes (5-15% or 50,000 – 150,000 mg/kg). Such concentrations, found at the earth’s surface and underground, are being exploited as ore bodies.

ZINC DEPOSITS

Zinc ore deposits are widely spread throughout the world. Zinc ores are extracted in more than 50 countries. China, Australia, Peru, Europe and Canada are the biggest zinc mining countries. Zinc occurs normally associated with lead and other metals including copper, gold and silver. There are four major types of zinc deposits:

1. Volcanic hosted massive sulphides (VMS)VHMS deposits are polymetallic and are an important economic source of copper and zinc often associated with significant concentrations of silver, gold, cadmium, bismuth or tin.

2. Carbonate hosted (Mississippi Valley & Irish types)Limestone and dolomite are the most common host rocks. The zinc lead content usually ranges from 5% - 10% with zinc usually predominating over lead. Concentrations of copper, silver and barite of fluorite may also be present.

3. Sediment hosted (sedex deposits)The host rocks are mainly shale, siltstone, and sandstone. Sedex deposits represent some of the world’s largest accumulations of zinc, lead and silver. The mineral has a high silver content. The lead/zinc content ranges from 10-20%.

4. Intrusion related (high sulphidation, skarn, manto, vein)These deposits are typically found in carbonate rocks in conjunction with magmatic-hydrothermal systems and are characterized by mineral association of calcium and magnesium. Typically the ore body contains more lead than zinc and is associated with silver.

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ZINC MINERALS

The most commonly found zinc mineral is sphalerite (ZnS) also known as zinc blende, which is found in almost all currently mined zinc deposits. The mineral crystallizes from the hydrothermal solution as purezinc sulphide.

The mineral marmatite is a complex zinc-iron sulphide, which is commonly found but rarely exploited as it is not easy to smelt.

Zinc deposits close to the earth’s surface are often converted to oxides and carbonates. Small quantities of zinc carbonate, the mineral calamine (smithsonite) In North America the mineral calamine often refers to the hydrated silicate mineral also known as hemimorphite.

Iron and lead sulphides, in the form of the minerals pyrite and galena are always associated in significant quantities while smaller quantities of other metals are commonly found.

Metamorphically formed oxide zinc ores such as franklinite or zincite are limited to only a few deposits.

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THE PRODUCTION OF ZINC

Zinc Mining

80% of zinc mines are underground, 8% are of the open pit type and the remainder is a combination of both. However, in terms of production volume open pit mines account for as much as 15%, underground mines produce 64% and 21% of mine production comes from the combined underground and open pit mining.

Rarely is the ore, as mined, rich enough to be used directly by smelters; it needs to be concentrated. Zinc ores contain 5 -15% zinc. To concentrate the ore it is first crushed and then ground to enable optimal separation from the other minerals. Typically, a zinc concentrate contains about 55% of zinc with some copper, lead and iron. Zinc concentration is usually done at the mine site to keep transport costs to smelters as low as possible.

Roasting & Sintering

Over 95% of the world’s zinc is produced from zinc blended (ZnS). Apart from zinc the concentrate contains some 25-30% or more sulphur as well as different amounts of iron, lead and silver and other minerals. Before metallic zinc can be recovered, by using either hydrometallurgical or hydrometallurgical techniques, sulphur in the concentrate must be removed. This is done by roasting or sintering. The concentrate is brought to a temperature of more than 900°C where zinc sulphide (ZnS) converts into the more active zinc oxide (ZnO). At the same time sulphur reacts with oxygen giving out sulphur dioxide which subsequently is converted to sulphuric acid – an important commercial by-product.

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The Hydrometallurgical Process

In a leaching stage the zinc oxide is separated from the other calcines. Sulphuric acid is used to do this. The zinc content dissolves whereas iron precipitates and lead and silver remain undissolved. However, the dissolved solution contains some impurities which need to be eliminated in order to obtain a high-purity zinc product at the end of the production process. Purification is mainly done by adding zinc dust to the solution. As all the elements to be removed lie below zinc in the electrochemical series they can be precipitated by cementation. The thus obtained purified solution passes an electrolytic process where the purified solution is electrolyzed between lead alloy anodes and aluminum cathodes. An electrical current is circulating through the electrolyte by applying an electrical difference of 3.3 – 3.5 volts between the anode and cathode causing the zinc to deposit on the aluminum cathodes in high purity. The deposited zinc is stripped off, dried, melted and cast into ingots. The zinc ingots may have different grades: High Grade (HG) 99.95 % and Special High Grade (SHG) 99.99% of zinc.

Today over 90% zinc is produced hydrometallurgical in electrolytic plants.

The Hydrometallurgical Process

The Imperial Smelting Process has been the most important hydrometallurgical process. It allows simultaneous production of zinc and lead metals – roughly 1 ton of lead for every 2 tons of zinc. It is particularly indicated for treating concentrates with a significant amount of lead. The Imperial Smelting process is based on the reduction of zinc and lead into metal with carbon in a specially designed Imperial Smelting furnace. Pre-heated air is blown from below in the shaft furnace. The sinter is charged together with the pre-heated coke at the top of the furnace. Temperatures range from 1000°C at the top to 1500°C or more in the center of the furnace. The coke is converted into carbon monoxide which provides the means to reduce zinc and lead oxides to metallic zinc and lead. The lead which is below its boiling point, flows from the bottom of the blast furnace, carrying copper, silver and gold with it. Zinc evaporates and passes out of the furnace near the top along with other gases. To avoid that it oxidizes back to zinc oxide the zinc vapor is rapidly quenched and dissolved in a spay of molten lead in a condenser (lead splash condenser). By cooling the lead, crude zinc is released and is separated. The lead returns to the condensing process for another cycle of dissolving and then releasing ore zinc.

The IS process is an energy-intensive process and thus became very expensive following the rise of energy prices in recent years. This and the lower production of bulk concentrates containing significant amounts of lead led to abandoning more and more the Imperial Smelting process. Today, Imperial Smelting furnaces are only in operation in Japan, China and Poland.

The major difference of the hydrometallurgical process and the Imperial Smelting process is that the first produce very pure zinc directly whereas the latter produces lower grade zinc that still contains significant impurities that have to be removed by thermal refining in the zinc refinery.

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ZINC PRODUCTION

There are zinc mines throughout the world, with the largest producers being China, Australia and Peru, in that order. In 2005, China produced almost one-fourth of the global zinc output, reports the British Geological Survey. The largest producing zinc mine in the world is the Red Dog Mine located in Northwest Arctic Borough, Alaska and operated by Teck-Cominco. This massive mine produces over 600,000 metric tons of zinc concentrate per year. World Zinc production grew by 4% to 10.7 million tones in 2006. An additional 640,000 tones of Zinc metal is forecast to be produced in 2007, enabling a 6% rise in total output to 11.3 million tones. The increase in global production will come from a number of mine expansions and new projects that, in turn, reflect growing explorations budget in recent years. Global exploration budget have increased by approximately 150% since 2002.Increases to supply are expected to come on line progressively over the medium term. For example, San Cristobal in Bolivia (capacity of 167000 tones a year) and Cerro Lindo in Peru (capacity of 110000 tones a year) are both due to be commissioned in the third quarter of 2007. Herald Resources’ 220 000 tonnes a year Dairi mine in Indonesia is yet another mammoth project. EuroZinc is also planning to restart the Aljustrel mine (80 000 tonne capacity) in Portugal. Over the medium term, four large confirmed projects in Canada, Mexico, the Russian federation are projected to addan extra 700000 tonnes to global capacity. In addition to this, a number of smaller projects, amounting to at least 400 000 are also expected to be completed. This increase in capacity, combined with the new projects and expansions in 2007, is projected to result in world Zinc production reaching 13.9million tonnes by 2012. Production in Canada is forecast to increase significantly as a number of new mines start up, with expected capacity of approximately 330000 tonnes a year. Three projects are dueto start production in 2007, increasing Canadian output in short term by around 120000 tonnes. However the largest project, the Perseverance mine, owned by Xstrata, which is expected to produce 115000 tonnes Zinc a year, is not forecast to start up until 2009. Over the medium to long term, countries in Africa may emerge as major producers of Zinc. International investment by Chinese and Australian companies in African continent has already begun to pay off.

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GRAPHICAL REPRESENTATION OF WORLWIDE ZINC MINE PRODUCTION GEOGRAPHICHAL DISTRIBUTION OF ZINC MINE PRODUCTION

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GRAPHICAL REPRESENTATION OF WORLDWIDE ZINC METAL PRODUCTION

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TOP ZINC PRODUCING COUNTRIES*

TOP ZINC CONSUMING COUNTRIES

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PRODUCTION OF ZINC IN INDIA

India was one the first countries that started the process of extracting and smelting zinc. Since that time, the country is producing this metal and is one of the oldest countries to do that. Though, India is not a leading player in the production zinc but it is moving in the direction to get self reliant in this context. India has approximately 4.3% share in the total zinc smelter capacity in the Asia pacific region. The largest company, which was indulged in the production of zinc, is a public sector company named Hindustan Zinc Limited. But now, ever since the company got privatized, the Indian industry is completely in the hands of the private sector. It can be said that the zinc industry in India, after privatization, is heading towards a major expansion programme. The major zinc mines in India which were under the control of the company are

Rampura Agucha mine Rajpura Dariba mine

Zawar mine

The smelting plants in India engaged in the production of zinc metal are

Chanderia Lead Zinc Smelter (CLZS) – Rajasthan Debari Zinc Smelter (DZS) – Rajasthan

Dariba Smelting Comples(DSC),Rajasthan

Vizag Zinc Smelter (VZS) – Andhra Pradesh

Binani Zinc Smelter – Kerala

Indian zinc market

As India was one of the first countries to gain the knowledge of extracting zinc from zinc ores and start the production of zinc metal, it should have been an important player in the world zinc market but this is not the current situation. India’s reputation regarding zinc is not significant as it just produces a small share of the metal in the world’s production and is not able to satisfy its domestic consumption demand making it a net importer of zinc. Zinc production in India was in the hands of the government initially as all the operations in India relating to the metal were in the hands of a public sector company – Hindustan Zinc Limited. It was the biggest company in India, which took care of zinc extraction and its smelting process. But in April 2002, this company was privatized in favor Sterlite group and after that the Indian industry is in the hands of private sector completely. The current Indian demand for zinc stands at around 3.5 lakh tons that is fulfilled with the help of domestic production and imports too. About 70% of the Indian demand comes from the galvanizing sector. After privatizing the zinc sector it is expected that by 2010 the country would become self-reliant to satisfy the domestic demand. After that, India may transform into a net exporter of the metal.

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ZINC AND ITS USES

Zinc Coatings on Steel

One of the biggest uses of zinc is in making protective coatings for steel. The development of the wide range of zinc coatings arose from two happy accidents of chemistry, the relatively slow and predictable rate of atmospheric corrosion of zinc compared with steel, and the relative positions of zinc and iron in the electrochemical series. Zinc will corrode preferentially to give cathodic protection to iron when both are in contact in an aqueous medium. This is used to good effect to protect immersed structures such as ships’ hulls, drilling rigs and pipelines. It also means that any bare areas in a zinc coating on steel, caused by damage or operations such as cutting or drilling, are still protected by the surrounding zinc.

Taken together, these two factors provide the basis of a unique corrosion protection system which uses some 4 million tonnes of zinc annually to protect around 100 million tonnes of steel. This represents almost half the total world consumption of zinc.

Other Zinc Coatings

Originally, zinc coatings were applied by hot dip galvanizing. This involves dipping prepared steel in molten zinc, figure 1. This was done mainly with fabricated steel or with sheets of steel, many of which were profiled to produce the ubiquitous ‘corrugated iron’. The first development from this was the production of continuous strip steel with a galvanized coating. Refinements of this process today account for the greatest part of steel carrying zinc coatings.

Other processes are available and are used where their specific characteristics are required. These include electroplating (also known as electrogalvanizing), flame sprayed coating, sherardising, mechanical plating and using zinc rich paints.

Recent Zinc Galvanising Alloys

Process developments in continuous galvanizing have enabled a range of coatings to be produced with very closely controlled thickness and surface finish. These can be formed and joined without

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significant damage to the protective coating. Along with these developments, a series of alloys for coatings have been produced. The most important of these are Galvalume and Galfan. Galvalume consists of about 55% aluminium and 45% zinc with a small amount of silicon. It is being used extensively around the world as it has better atmospheric corrosion resistance than pure zinc however, it loses the ability to protect any exposed steel such as that at cut edges. Galfan is a zinc, 5% aluminium alloy containing small amounts of rare earth metals which has a substantial and growing niche market in which its properties are valuable. Its corrosion resistance is better than that of zinc and it retains some cathodic protection capability.

Zinc Batteries

Zinc based energy systems have tremendous advantages including high specific energy, recyclability, safety and zero emissions.

Its not surprising then that zinc is used in the manufacture of a variety of battery chemistries, both primary and rechargeable, consumer and industrial.

The most well known of these chemistries are the primary zinc-carbon and alkaline batteries, which together dominate the standard AAA, AA, C and D size consumer battery market.

Zinc/Air and Zinc/Silver batteries are also widely used in the electronics industry to power hearing aids, wrist watches, calculators and the like. Industrial Zinc/Silver and Zinc/Nickel batteries are of critical importance in a variety of aeronautic and military applications; while larger Zinc/Air cells have been developed to power electric vehicles and Remote Area Power Supply (RAPS) installations.

The zinc air cell is a particularly interesting technology because it acts as a partial fuel cell using the O2 from air as the cathode. There are portable primary zinc/air batteries and industrial primary zinc/air batteries. There are also electrically rechargeable zinc/air batteries that use a bifunctional oxygen electrode for charge and discharge, and mechanically rechargeable zinc/air batteries that require the replacement of discharged anodes.

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Zinc Use in Brass

The Brass Family

Brass is not a single unique metal. Rather, the brasses comprise a family of copper-base alloys in which zinc is the principal alloying element. The amount of zinc present in these alloys ranges from 10% to more than 40%. Besides its traditional use for door handles, lighting fixtures and decorative objects, brass is now an increasingly popular material with architects, interior designers and consumers.

Brass has a warm, natural colour and feel. Brass is also a hygienic material - when used for handles, railings and hardware, it has the added benefit of being bacteriostatic.

The names given to alloys in the brass family are, in some cases, as colorful as the metals themselves. Historically and technically, brass is defined as any alloy in which the principal constituents are copper and zinc. Thus, all brasses contain zinc, although other elements may be present.

That convention notwithstanding, design parlance collectively identifies all of these alloys as "bronzes", mainly because of their similar uses, colors and weathering characteristics. For example, designers and architects speak of "white bronzes", "yellow bronzes", "statuary bronzes" and even "green bronzes" (after weathering). In fact, the majority of the metals so identified are brasses, or alloys of copper and zinc.

Cast brasses offer almost infinite possibilities for artistic expression, not simply for statuary, but as decorative hardware, innovative plumbing fixtures and architectural details. Moreover, cast brasses can be selected by color to match - or contrast - the colors of most wrought brass alloys, an important advantage.

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Ageless beauty

The brasses we normally think of are bright yellow in color. Brasses can retain that color indefinitely if properly protected with suitable finishes, but the way brasses change color as they age opens an entirely new dimension to their use in architecture. The very pleasing - and from a corrosion standpoint, very protective - natural patinas that brasses assume as they age have become synonymous with durability and lasting quality. Architects, designers and sculptors take creative advantage of brass's gradual change in appearance to underscore the timelessness of their structural creations.

Today, it is possible to accelerate brass's ageing process through the application of chemical

treatments. These "artificial patinas" create within hours the protective mineral surface finishes that would take decades to form in nature. Alternatively, durable lacquers and polymeric laminates are now available that can retain the natural beauty of new metal for years, whether indoors or exposed to the atmosphere. The recent development of extremely age-resistant protective finishes, including powder coatings and vapor-deposited organic coatings, is one of the major driving forces behind brass's growing popularity. Interestingly, some architects have found that the combination of aged patinas and bright "new" metal finishes is especially appealing. The variety of surface finishes and colors available in brass is one more expression of the metal's almost endless variety.

Environmentally friendly

Finally, it is important to understand that brass is an environmentally friendly metal. Its constituents, copper and zinc, are produced today by energy-efficient processes. More important, though, is the fact that brass is one of the most thoroughly and efficiently recycled of all industrial metals. When brass articles are no longer needed, they are almost never discarded, and brass rarely, if ever, finds its way to a landfill. Rather, brass is remelted and reprocessed to "new" brass many times over. It is simply too valuable to throw away. The efficient recycling process has been going on for thousands of years. Think about that the next time you see a brand new brass product - its family tree may include recycled products that are centuries old.

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Zinc Compounds

In the chemical industry zinc is used in the form of zinc powders and dusts. These are prepared by pulverizing a stream of molten metal in a jet of compressed air or water. The difference between powder and dust is essentially a matter of fineness, dusts being finer. They are used to purify solutions by cementation or to achieve other reductions. Special grades of zinc powders are also used in alkaline batteries as well as in certain button cells.

The electrochemical properties of zinc account for its essential role as a negative electrode in dry (or Leclanché) batteries.

Zinc oxide ZnO, the most widely used zinc compound, is produced by two different methods: the direct or American process, which starts from oxidized materials and involves a reduction step with carbon, followed by oxidation of the zinc vapor in air, and the indirect or French process, which starts from zinc metal and gives a higher purity end product. Zinc oxide is used in the vulcanization of rubber, as well as in ceramics, paints, animal feed and pharmaceuticals, and many other products and processes. A special grade of zinc oxide has long been used in photocopiers. The oxide is also used in varistors (that provide protection against over-voltages).

Zinc sulphide ZnS mixed with barium sulphate is used as a white pigment known as lithopone. ZnS is also used as a detector of alpha-rays, which render it luminescent.

ZnS and the selenide ZnSe are used in infrared optics.

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Zinc salts have various applications: zinc chloride in the textile industry, in the manufacturing of Leclanché batteries, and as a scaling flux in galvanizing; zinc sulphate in agriculture and animal feed; zinc phosphate to passivate steels, etc. Organic salts of zinc are used in paints, and zinc stearate is used in the preparation of plastics as well as in powder metallurgy.

Zinc Die Castings

IntroductionDie Castings are among the highest volume, mass-produced items manufactured by the metalworking industry. From bathroom fixtures and door and window hardware to office equipment and tools as well as automotive and countless electronic components, zinc castings are truly everywhere and positively impact our lives on a daily basis.

Why Zinc Castings?

For countless decorative and functional applications no other material and process can match the properties and economics of zinc die casting.

Zinc casting alloys are stronger than reinforced molded polymers and zinc's hardness, self lubricating properties, dimensional stability and high modulus make it suitable for working mechanical parts, such as gears and pinions, that would be less durable if molded from polymers. Zinc’s excellent thermal and electrical conductivity, as well as precise casting tolerances, make it an ideal material choice for heat sinks, electrical components and applications requiring electromagnetic shielding. Zinc can be cast at moderate temperatures thus providing significant energy and processing savings over other metals and engineering alloys.Zinc castings also accept a broad assortment of finishes allowing almost any desired aesthetic characteristic and coating durability to be achieved. For example, zinc castings can be made to look like solid gold, weathered brass, stainless steel, and even leather And,

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because of zinc’s density, cast zinc parts provide a feel of substance and durability that simply cannot be matched by plastic components.

Key Advantages of Zinc Casting Alloys include:

Process Flexibility: Virtually any quantity and quality requirement. Precision, high-volume die casting is the most popular casting process. Zinc alloys can also be economically gravity cast for lower volumes using sand, permanent Virtually any casting process can be used with zinc alloys to satisfy mold, graphite mold and plaster casting technology.

Precision Tolerances: Zinc alloys are castable to closer tolerances than other metals or molded plastics, therefore presenting the opportunity to reduce or eliminate machining. "Net Shape" or "Zero Machining" manufacturing is a major advantage of zinc casting.

Strength & Ductility: Zinc alloys offer high strengths (to 60,000 psi) and superior elongation for strong designs and formability for bending, crimping and riveting operations.

Toughness: Few materials provide the strength and toughness of zinc alloys. Impact resistance is significantly higher than cast aluminium alloys, plastics, and grey cast iron.

Rigidity: Zinc alloys have the rigidity of metals with modulus of elasticity characteristics equivalent to other die castable materials. Stiffness properties are, therefore, far superior to engineering plastics.

Anti-Sparking: Zinc alloys are nonsparking and suitable for hazardous location applications such as coal mines, tankers and refineries.

Bearing Properties: Bushing and wear inserts in component designs can often be eliminated because of zinc's excellent bearing properties. For example, zinc alloys have outperformed bronze in heavy duty industrial applications.

Easy Finishing: Zinc castings are readily polished, plated, painted, chromated or anodized for decorative and/or functional service.

Thin Wall Castability: High casting fluidity, regardless of casting process, allows for thinner wall sections to be cast in zinc compared to other metal.

Machinability: Fast, trouble-free machining characteristics of zinc materials minimize tool wear and machining costs.

Low Energy Costs: Because of their low melting temperature, zinc alloys require less energy to melt and cast versus other engineering alloys.

Long Tool Life: Low casting temperatures result in less thermal shock and, therefore, extended life for die casting tools. For example, tooling life can be more than 10 times that of aluminum dies.

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Clean and Recyclable: Zinc alloys are among the cleanest melting materials available. Zinc metal is non-toxic, and scrap items are a reusable resource which are efficiently recycled.

Galvanizing

1. Introduction

For over a century, zinc has enhanced the longevity and performance of steel. Zinc coatings provide the most effective and economical way of protecting steel against corrosion which, left unchecked, is estimated to cost an industrialized country’s economy at least 4% of GDP each year.

Zinc-coated or galvanized steel offers a unique combination of properties unmatched by any other material. These include:

high strength formability

light weight

corrosion resistance

aesthetics

recyclability

low cost

For this reason, galvanized steel sheet is an ideal material for a multitude of building and manufacturing applications - from automobiles to household appliances to residential, commercial and industrial construction.

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This section describes the continuous galvanizing process, products, coating performance and the environmental characteristics of zinc coatings. Other zinc coatings in addition to continuous galvanizing are also briefly discussed.

Total coated sheet steel capacity 1970 - 2000, in millions of metric tons

2. Technical Performance of Zinc Coatings

There are many factors to consider when selecting the most appropriate zinc coating. In addition to corrosion protection, the coating’s formability, adherence, appearance and cost should also be considered. These factors each impact on selecting the correct zinc coating for a given application. All zinc coatings, like the steel they protect, are recyclable.

2.1. Corrosion Resistance: When left unprotected, steel will corrode in almost any environment. Zinc coatings protect steel by providing a physical barrier as well as cathodic protection for the underlying steel. It is important that the correct zinc coating is specified to provide optimal performance under the exposure conditions to which the coating will be subjected.

2.1.1. Barrier Protection: Zinc coatings provide a continuous, impervious metallic barrier that does not allow moisture to contact the steel. Without moisture, there is no corrosion, except in certain chemical atmospheres. The effectiveness of zinc coatings in any given environment is directly proportional to coating thickness. Coating life is determined by the coating corrosion rate, itself a function of many factors such as time, composition of the atmosphere and the type of coating.

In situations of outdoor exposure, the acidity level of rain will influence the zinc corrosion rate. With indoor exposure - ventilation ducts, floor decks and steel framing, for example - moisture may also be present. In industrial indoor situations, the atmosphere may be corrosive. Thus the type and weight of coating required depends both on the service life needed and the exposure conditions.

Corrosion resistance of coatings can also be improved by using a zinc alloy coating, such as Galfan® or Galvalume®, or by applying paint top coats. These two methods, individually or together, are recommended for exposed sheet applications where enhanced corrosion protection is required.

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2.1.2. Cathodic Protection: Another outstanding protection mechanism is zinc’s remarkable ability to galvanically protect steel. When base steel is exposed, such as at a cut edge or scratch, the steel is cathodically protected by the sacrificial corrosion of the zinc coating adjacent to the steel. In practice, this means that a zinc coating is not undercut because the steel cannot corrode adjacent to a zinc coating. This contrasts with paint and aluminum coatings where the corroding steel progressively undercuts the surrounding barrier film. The extent of this cathodic protection is determined by the type of coating, its thickness and that of the underlying steel, as well as by the area of damage.

When painted zinc-coated steel is scratched, zinc protects both the underlying steel from corrosion and the overlying paint coat from lifting.

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Source: IISI Growth of corrosion of painted cold-rolled and painted galvanized steel sheets used for car body

outer panel.

2.1.3. Painted Zinc Coatings: Zinc coatings are easily painted. The term "duplex coating" is used for galvanized and painted steel parts, whereas the term "coil coating" or "pre-painting" is used for continuous galvanized and painted steel sheet. Paint acts as a barrier protecting the underlying zinc coating. Zinc is an excellent substrate for paint coatings because if the paint film is broken, zinc’s high corrosion resistance prevents undercutting of the paint film. Even if the coating damage does reach the steel base, zinc’s cathodic action will prevent the steel from corroding. Zinc’s ability to extend the life of paint coatings is what makes pre-painted galvanized steel sheet such a durable product that continues to extend its market share in commercial and residential roofing and cladding applications.

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Combigram of duplex systems.The zinc and steel industries have for many years conducted both research and field trials on the

performance of various combinations of painted and coated sheet steel. The result of this extensive base of information is that existing performance can be predicted for a wide range of atmospheric conditions. In the example shown for a highly corrosive industrial atmosphere, a 70 µm galvanized

coating plus a 100 µm layer of paint will provide a coating life of over 50 years. Similar evaluation can be made for other coating combinations and atmospheric conditions.

Source: Stichting Doelmatig Verzinken / Progalva

2.2. Formability and Adhesion: The formability and adhesion of continuous galvanized zinc coatings are excellent and in most cases match the formability of the underlying steel. The formability of galvanized steel - which is defined as the resistance to cracking and loss of adhesion of the zinc coating during forming - is inversely proportional to coating and steel substrate thickness. There are, however, some coatings that are more ductile than others, an important consideration for deep draw stamping applications. It is therefore necessary to balance the requirements for corrosion resistance and formability .

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2.3. Surface Appearance: Zinc and zinc alloy coatings can differ in appearance depending on customer needs and consumer preferences. Galvanized coating finishes can vary from extra smooth and featureless to a flowery "spangle" pattern. Galvanneal (Zn-Fe) coatings have a matt grey appearance. Electrogalvanized coatings have the smoothest finish among zinc coatings and provide the best substrate for a high quality paint finish.There are standards covering all aspects of surface appearance - coating finishes, surface qualities (from regular to best quality) and surface treatments (chemical passivation, oiling) - all targeted to enhance further processing.

2.4. Assembly: Assembly refers to the technique of joining galvanized sheet steel products, mainly to themselves. In any application, the joining method should suit the metallic coating and will be determined either on the basis of its performance or the properties and characteristics of the

galvanized product.

There are several effective joining methods:

Welding is the most common method of joining steel products. Resistance welding is a technique that uses resistance to the flow of electrical current to generate heat and thereby join two materials. Pre-finished galvanized steel can be spot welded if the zinc coating is not too thick to enable the welding current to pass from one electrode to the other. This technique is often used in the downstream sectors. Mechanical fixing methods such as screws, rivets, self-piercing rivets and lock forming can be used for a wide range of steel substrate, zinc coatings and applications.

Adhesive bonding has become more popular and can also be allied to mechanical fixing. The range of adhesive systems is wide and the

selection depends on numerous variables such as surface condition, adhesion, strength and cure speed.

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3. Continuous Galvanizing

3.1. Products: Starting from high purity zinc, alloying elements can be added to produce galvanized coatings with different properties. These products can be used in a wide variety of applications and climates. The family of continuous galvanized coatings includes galvanized, electrogalvanized, galvanneal, Galvalume® and Galfan® coatings.

Galvanized: A pure zinc coating that is the standard continuous galvanized product typically used in building panels, steel framing, agricultural and automotive applications, as well as in numerous other functions. It has good surface finish and adhesion properties.

Electrogalvanized: Steel sheet with an electroplated zinc coating that has an ultra-smooth surface finish which is desirable for surface critical parts such as automotive exterior body panels. The coating thickness for electrogalvanized sheet is typically lower than for a hot-dip galvanized product. Electrogalvanized coatings generally use pure zinc although alloy coatings (Zn-Fe, Zn-Ni) are also commercialised.

Galvanneal: A zinc-iron alloy coating with improved paintability, weldability and drawability, Galvanneal is used in the automotive industry because of its improved manufacturing performance in models which use lighter and stronger grades of steel.

Galvalume: Galvalume is a zinc-55% aluminum alloy coating with superior corrosion resistance for applications without severe forming. It is widely used for painted and unpainted building panels and roofing and for higher temperature applications in vehicle powertrain and heat-reflective components.

Galfan: Galfan is a zinc-5% aluminum coating with superior corrosion resistance when formed. It is used for painted building panels and for severely formed components, such as automotive parts and domestic appliances intended for corrosive environments. Galfan coated steel is noted for its outstanding coating adhesion, making it ideal for deep drawn and "zero-thickness" bend applications.

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3.2. Aesthetics: Galvanized steel sheet can also be painted for improved corrosion protection and aesthetics. The most cost-effective and best quality painting method is continuous coil coating or pre-painting. This allows for exact preparation of the galvanized surface prior to coil coating. Painted galvanized sheet is roll-formed to give profiles specified by the customer. Recent advances in galvanizing technology and paint systems enable pre-painted galvanized sheet to be roll-formed with striking patterns, allowing architects new roofing and cladding possibilities for industrial, commercial and residential buildings. For example, roll forming and stamping are now used to make tile roofing, offering a product with much lower weight and cost than the traditional material.

A wide variety of paint systems are available to meet the performance requirements of a given application. Today’s automobiles have a perfect body finish that combines a high degree of aesthetic appeal with high standards of corrosion protection. Roll formed pre-painted sheet for building, cladding and roofing presents three main assets - the aesthetic appearance of sharp profile, long life and favourable economics.

Roll forming of pre-painted sheet gives a lower cost than painting after forming. Domestic appliances combine severe forming with guaranteed corrosion protection to meet the requirements of modern design. Steel sheet suppliers can provide advice on the most appropriate system for individual needs.

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3.3. Standards: Around the world, standards such as ISO, ASTM and JIS are available to assist in the specifying and purchase of galvanized steel sheet. The table below lists some of the more popular coating weights available in each product standard. For details of local standards, please refer to your steel supplier.

Range of Commonly Available Coating Weights.

3.4. Applications: The major uses of galvanized steel sheet are construction and vehicle and appliance manufacturing. Globally, galvanized sheet is a major constituent in the 50 million vehicles and over 40 million appliances produced each year, as well as in countless commercial and industrial buildings. A growing market is galvanized steel framing and roofing for residential buildings.

Today, there are over 550 continuous galvanizing lines worldwide and additional capacity is planned in response to growing demand.

Zinc-coated steel resists decay, corrosion, termites, fire, wind, floods and earthquakes better than any other construction material. For this reason, it is being used more and more in commercial and residential construction.

Common uses of coated steel sheet

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The growth in auto industry use of zinc-coated steel sheetSource: IZA-Europe

Photos: BHP Steel - Cockerill-Sambre - Cominco - Galvazinc Association - Usinor

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3.5. Economics: Zinc-coated steel sheet offers a unique combination of strength, durability, formability, recyclability and cost. Recyclability is a key selection criteria for specifiers. The existence of cost-effective recycling routes contributes favorably to the global cost of zinc-coated steel products.

The use of galvanized sheet for automotive body panels allows today’s automakers to guarantee up to 12 years’ corrosion resistance, while adding only a fraction of a percent to the cost of the vehicle. The cost-benefit ratio represents outstanding value for the consumer. The same applies to building panels - galvanized coil coated products are now available with up to 50 year performance warranties. The improved performance and added value generated by zinc coated steel sheet is vastly superior to the small additional production cost. Durability, aesthetics, longterm stability of surface appearance and low maintenance are all significant advantages for the final user.

In the construction industry, galvanized steel decking combined with high-speed concrete pouring allows faster construction, thereby lowering construction costs.

Commercial and industrial washing machines can operate every day around the clock thanks to galvanized steel sheet casings that resist wear and tear from exposure to soaps, bleaches and chemical solutions.

Galvanized steels can be stamped and formed using existing steel manufacturing equipment, thus avoiding the need for costly new tooling - in this way, galvanized steel contributes to manufacturing economies.

Thicker coatings are more expensive than thinner coatings and zinc alloy coatings are more expensive than galvanized coatings. In both cases, however, these premium products give higher performance. The extra cost involved is small when compared to improvements in performance. Choices are best made by matching coating performance to application needs.

Galvanized steel is a value-added product that allows the use of steel sheet in applications where uncoated steel could not be used. Zinc coatings help expand the markets for steel.

3.6. The Process: Continuous galvanized steel is made under precise, factory-controlled conditions during which flat rolled steel coils are upgraded to high-quality, zinc-coated steel using high-speed continuous lines that control not only the coating quality but also the strength and formability of the steel product. Zinc is applied either by dipping in molten zinc or by electroplating.

In the continuous hot-dip galvanizing process, coils of rolled steel are continuously unwound and fed through cleaning and annealing sections before entering a molten zinc bath at speeds up to 200 metres per minute (650 feet/minute). As the steel exits the molten zinc bath, gas "knives" wipe off the excess coating from the steel sheet to control coating thickness. The steel strip then undergoes a series of mechanical or chemical treatments. Depending on customer requirements, the coated sheet steel can be passivated, oiled and recoiled, and cut to length and palletized before shipment to the fabricator. All galvanized coatings are metallurgically bonded to the steel they protect. This ensures coating adhesion - critical for manufacturing processes that stamp, roll or draw the steel into its final product shape.

Electrogalvanized coatings are produced by electroplating zinc or zinc alloys onto steel in a continuous process. The major use of electrogalvanized coatings is autobody outer panels, although other automotive structural components such as inner panels, doors, housings and appliances are also produced from this material.

Continuous Hot Dip Galvanizing LineCourtesy of DNN Galvanizing Corporation, Ontario, Canada

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Key: 1. Entry Gauge - 2. Double Cut Shear - 3. Welder - 4. Cleaning - 5. Entry Looping Tower - 6. Preheat Furnace - 7. Direct Fired Furnace - 8. Radiant Tube Furnace - 9. Gas Jet Cooling - 10. Controlled Cooling - 11. Zinc Pot - 12. Air/Nitrogen Wiping - 13. Galvannealing Furnace - 14. Tower Roll Clean - 15. - Quench Tank - 16. Water Cooling Dryer - 17. Coating Weight Gauge - 18. Temper Rolling -19. Tension Leveller - 20. Skinpass Mill Dryer - 21. Delivery Looping Tower - 21. Electrostatic Oiler - 23. Flying Shear - 24. Tension Reel - 25. Coil Cars - 26. Scale and Automatic Shipping

5. Other Zinc Coatings

5.1. General Galvanizing: General Galvanizing, also known as Hot Dip Galvanizing, After-Fabrication Galvanizing or Batch Galvanizing, refers to the galvanizing of fabricated or manufactured steel items. The fabricated steel article is cleaned and then dipped into a molten zinc bath, either on racks for small items or individually for large items.

Zinc coatings from this process are five to ten times thicker than continuously galvanized coatings and can offer long term outdoor protection in most environments. This resistance can vary from 20 years in an industrial site to over 65 years in a rural environment.

General galvanizing provides fabricated steel items with excellent protection against corrosion. The nature of the immersion process provides good edge protection and complete coverage of the outer surface area as well as inner protection of hollow parts. In general, a zinc coating of at least 60-70µm is applied.

Every year, worldwide, more than 10 million tonnes of steel products are protected against corrosion by the general galvanizing process.

5.2. Particulate Applied Zinc Coatings: Zinc can also be applied to steel by zinc metallizing, or by adding zinc dust to paint systems.

5.2.1. Metallizing: Zinc metallizing, or thermal spraying, is a process by which zinc wire, or powder, is fed into a spray gun, melted and sprayed onto a work piece. Melting is accomplished either by combustion in an oxygen-fuel gas flame, or by an electric arc that is created between two zinc wires. The resulting metallic coating is slightly porous with a lamella or layered structure. Metallized

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coatings can be applied at high thickness (100–200 µm) which makes them ideal for long-term corrosion protection.

5.2.2. Mechanical Plating: This process is used primarily for small (<0.5kg) threaded work or other close tolerance items. The parts to be plated are tumbled together with zinc powder and glass beads in water. The tumbling action causes the glass beads to hammer the zinc onto the part. This process eliminates the possibility of hydrogen embrittlement of high strength fasteners. Coating thickness is controlled by time and quantity of zinc powder added.

5.2.3. Sherardizing: Sherardizing is a diffusion controlled process which produces a zinc iron alloy coating. Small fabricated articles are charged in a drum with zinc powder and sand. The drum is rotated at a temperature below the melting point of zinc, typically 380˚C, for up to 3 hours. Uniform, hard, abrasion resistant coatings can be formed on complex parts.

5.2.4. Zinc-Rich Paint: Zinc-rich paint typically contains over 77% zinc in the dry film and benefits from the barrier and cathodic protection provided by zinc. Zinc-rich paints are classified as organic, or inorganic, depending on the binder used. They can be applied by brush or spray and must always be applied over a properly prepared steel substrate.

6. Zinc-Coated Steel is an Environmentally Responsible Choice

All types of zinc-coated steel products are recyclable. Both the technology and recycling capacity have been developed in response to environmental awareness and the need for cost-effective, alternative supplies of raw material for the steel and zinc industries. Once steel is galvanized, zinc becomes part of the steel recycling circuit. The Electric Arc Furnace (EAF) is the principal recycling route for zinc-coated steel, producing new steel and zinc that return to the market place.

Zinc-containing EAF dust is treated and the zinc recovered in the form of zinc oxide, which is in turn used for producing zinc, which is then re-used for galvanizing. This closed-loop recycling route is widespread today in industrialised countries. New cost-effective treatment technologies continue to be developed with the aim of maximising zinc recovery. Today, 80 percent of the zinc available for recycling is indeed recycled.

Galvanized steel is recycled from three sources: scrap arising during the production of galvanized sheet

scrap generated during product manufacturing and installation

end-of-life products, whose availability for recycling is a function of product life-span, for example: 12-15 years for cars versus 25-100 years for building products.

The amount of galvanized scrap steel available for recycling has been rising over the last ten years. The majority of galvanized steel sheet, however, is still in the marketplace in the form of cars, appliances and building products although more and more is now becoming available for recycling. Building product applications - the largest market for galvanized steel sheet - remain in service for many years before recycling. It is only recently that some of the lower life-span galvanized products,

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such as automobiles, have started entering the recycling circuit. Over the next ten years, the supply of zinc-coated steel scrap is expected to increase by more than 50%, with the highest increase coming from the automotive sector.

Zinc Sheet

Zinc sheet is used extensively in the building industry for roofing, flashing and weathering applications. Architectural alloys generally contain copper and titanium and are produced in the form of sheet, strip, plate and rods and are used as such, or cut and formed to desired shapes, such as gutters, cornices and pipes. Zinc sheet is also used in graphic art to make plates and blocks, as well as battery cans and coinage.

Today, zinc sheet is typically produced by continuous casting/rolling. Zinc is melted in an induction furnace, and the molten metal is poured between the two endless bands of a Hazelett machine, where it solidifies. The continuous 'ingot' delivered at the other end can be more than 1 m wide and from 10 to 20 mm thick. The endless strip is fed continuously to a rolling mill, which reduces the thickness to the desired level in successive passes, after which it is cut to size and coiled.

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Zinc sheet allows architects the freedom to create highly complex roof designs

The United State's Penny is made from copper-plated rolled zinc (97.5 Zn , 2.5 Cu)

ABOUT HINDUSTAN ZINC

HISTORY

Hindustan Zinc Limited was incorporated from the erstwhile Metal Corporation of India on 10th

January 1966 as a Public Sector Undertaking. In April 2002, Sterlite Industries (India) Limited made

an open offer for acquisition of shares of the company consequent to the disinvestment of

Government of India’s stake (26%) including management control to Sterlite and pursuant to the

regulations of SEBI Regulations 1997 acquired additional 20% of shares from public.

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In August 2003, Sterlite Industries acquired additional shares to the extent of 18.92% of the paid up

capital from Government of India (GOI).

Milestones (Post Disinvestment)

2007 Chanderiya Hydrometallurgical Zinc Smelter (Hydro II) commissioned

o 63.2 MW Wind Energy Project commissioned

2006 Chanderiya Ausmelt Lead Smelter commissioned.

o Sindesur Khurd Mine began production.

2005 Chanderiya Hydrometallurgical Zinc Smelter (Hydro I) commissioned along with a 154

MW coal based captive power plant.

2003 Sterlite Industries acquires 18.92% stake in Hindustan Zinc from Government of India

2002 Sterlite acquired 26% stake in Hindustan Zinc from the Government of India.

Consequent to disinvestment a further 20% is bought from market through open offer.

Our Board

Shri Agnivesh Agarwal, Chairman.

Smt. Ajita Bajpai Pande, Director

Shri S. K. Mittal, Director

Shri A. K. Singh, Director

Shri Nand Kishore Shukla, Director

Shri Anil Agarwal, Director

Shri Navin Agarwal, Director

Shri K. K. Kaura, Director

Shri Tarun Jain, Director

Shri M.S. Mehta, CEO & Whole-time Director

HIGHLIGHTS

One of the world’s largest integrated zinc and lead producer

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Refined zinc production capacity 669,000 tonnes per annum

Refined lead production capacity 85,000 tonnes per annum

Operational Highlights of Hindustan Zinc

Vision & Mission

VisionBe a world-class zinc company, creating value, leveraging mineral resources and related core

competencies.

Mission

Be a lowest cost zinc producer on a global scale, maintaining market leadership

One million tonne zinc-lead metal capacity by 2010

Be innovative, customer oriented and eco-friendly, maximizing stake-holder value

Assets & Locations

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Hindustan Zinc is a vertically integrated company with mining and smelting operations located mainly in the

State of Rajasthan and in the State of Andhra Pradesh

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OPERATIONS

MINING

Rampura Agucha Mine

Commissioned 1991

Location 225 km north of Udaipur, Rajasthan, India

Capacity 5.00 million tonnes per annum ore

Details An open cast mine and good ore grade leading to higher recovery and

overall low cost of production. Onsite concentrator to produce Zinc

concentrates.

Certifications ISO 9001:2000, ISO 14001:1996, OHSAS 18001:1996

Rajpura Dariba Mine

Commissioned 1983

Location 75 km north-east of Udaipur, Rajasthan, India


Rajpura Dariba Mine An underground mine with onsite concentrator and two vertical access

shafts. Mining is done through vertical crater retreat and blast hole

stoping. Ore is crushed underground before hoisting and stockpiling for

secondary and tertiary crushing.

Certifications ISO 9001:2000, ISO 14001:2004, OHSAS 18001:1999, SA 8000: 2001

Sindesar Khurd Mine

Commissioned 2006

Location 80 km north-east of Udaipur, Rajasthan, India


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SMELTING

Hindustan ZincLtd. operates smelters using, Roast Leach Electro-Winning (RLE), hydrometallurgical (Debari, Vizag and Chanderiya Smelters), ISP™ pyrometallurgical (Chanderiya Lead Zinc Smelter) and Ausmelt™ (Chanderiya Lead Smelter) process routes.

Chanderiya Lead Zinc Smelter Complex

Location 120 km from Udaipur, Rajasthan, India

Lead Zinc Smelter Commissioned in 1991

Imperial Smelting Technology – UK

Gone through a series of debotlenecking

105,000 tonnes per annum of Zinc

35,000 tonnes per annum of Lead

120 tonnes per annum of Silver

Hydrometallurgical

Zinc Smelter

Hydro I Commissioned in 2005

Roast Leach Electrowinning

Technology with Lead Silver Residue Recovery


Hydrometallurgical

Zinc Smelter

Hydro II Commissioned in 2007

Roast Leach Electrowinning

Technology with Conversion Process


Lead Smelter Commissioned in 2006

TSL Technology from Ausmelt-Australia

Cansolv Technology for Sulphur Recovery

50,000 tonnes per annum of Lead

Coal Based Captive

Power Plant

Commissioned in 2005

Built by BHEL

2 x 77 MW


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Built by BHEL

80 MW

Certification ISO 9001:2000, ISO 14001:2004, OHSAS 18001:1999

Highlights

Largest single location Zinc-Lead Smelter Complex in the World

World’s largest and latest generation roasters

State-of-The-Art DCDA acid plants & Tail Gas Scrubber.

Cansolv plant for 100% sulphur capture from Ausmelt Lead Furnace.

Residue management using Jarofix Technology

Zero discharge

Products Range

Special High Grade

Zinc (SHG)

- Slabs (25 kgs)

Jumbo (1,000 kgs)

Prime Western Zinc

(PW)

- Slabs (25 kgs)

Lead - Slabs (25 kgs)

Cadmium - Pencils (160 gms)

Silver - Bricks (30 kgs)

Sulphuric Acid - + 98.5%

concentration

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Debari Zinc smelter

Location 14 km from Udaipur, Rajasthan, India

Hydrometallurgical

Zinc Smelter


Roast Leach Electrowining Technology with Conversion Process



Captive Power

Generation

29 MW DG Set

Certifications BEST4 Certified Integrated Systems

ISO 9001:2000, ISO 14001:2004, OHSAS 18001:1999, SA

8000:2001

Highlights

DCDA acid plant & Tail Gas Scrubber.

Zero discharge

Products Range

High Grade Zinc

(HG)

- Slabs (25 kgs)

Jumbo (600 kgs)


Sulphuric Acid - + 98%

concentration

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Vizag Zinc smelter

Location 17 km from Vishakapatnam, Andhra Pradesh, India

Hydrometallurgical

Zinc Smelter


Roast Leach Electrowining Technology with Conversion Process



Certifications BEST4 Certified Integrated Systems

ISO 9001:2000, ISO 14001:2004, OHSAS 18001:1999, SA

8000:2001

Highlights

Acid plant with Tail Gas Scrubber.

Zero discharge

Products Range

High Grade Zinc (HG) - Slabs (25 kgs)


Sulphuric Acid - + 98% concentration

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Central Research & Development Laboratory

Establishment 1977

Location Located at Debari, 14 km east of Udaipur (Rajasthan)

Certification ISO 9001, 14001, OHSAS 18001 certified unit

Listed in American Society of Testing Materials (ASTM)’s Directory

of International Testing Laboratories.

Recognized laboratory from Department of Scientific and Industrial

Research (DSIR), Government of India

Objectives Establish Company’s image as a leading technology-driven company

through in-house development of path breaking technologies or by

working closely with technology leaders, universities, and research

institutions in India or overseas

Technology development for recovery of metal values from by

products, intermediates, waste and environment management

Act as Referral laboratory/ Umpire for export/ import consignment

and exploration

Facilities

Mineral Processing Batch Testing Facilities

Crushing, Grinding, Sizing, Gravity Separation, Froth-Flotation

Continuous Testing Facility

Portable continuous stage-flotation testing (Mini Flotation) unit along

with slurry pumping and reagent dosing

Mineral Processing Pilot Plant

Continuous basis, 2 TPD capacity, Stage-Crushing & Wet Grinding,

Froth Flotation, Wet / dry grinding ball mill 4 MT /day

Extractive Metallurgy Pyrometallurgy

Furnaces: Rotary Kiln, Pit furnace, Arc Furnace, High temperature

furnace

Hydrometallurgy

Pressure Autoclaves, lab scale leaching and downstream facilities

Kg scale leaching plant, Kg scale SX-EW plant

Bioleaching

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Laminar flow work-station, Autoclave, Incubators (Stationary and

shaking), Cooling centrifuge (Normal and high speed cooling),

Bioleaching Reactors, Bioleaching columns for bench scale testing.

Material Characterization/ Analytical

Petromineralogy Facilities

X-Ray Diffraction

X-Ray Fluorescence

Atomic Absorption Spectrophotometer

(with GTF and vapor generation unit)

UV-vis Spectrophotometer

Mercury Analyzer

Karl Fischer Apparatus for Moisture determination

Wet Chemical Analysis

Recent Achievements

Flotation Process development for new Lead-Zinc deposit.

Silver enrichment in Moore cake and its recovery. Recovery of Zinc

values from Tailing via Bioleaching route. Upgradation of Silver grade

in Lead Concentrate at Rampura Agucha Mine.

Simulation of crushing & grinding circuits for Mineral Beneficiation

plant for the automatic control of grinding circuits.

Process development for recovery of Cobalt oxide from Beta cake of

Debari Zinc Smelter.

Production of Copper Cement and recovery of Zinc from Copper

Cadmium cake of Chanderiya Lead-Zinc Smelter.

Mesh of Grind (MOG) studies for Hindustan Zincmines.

Recovery of Cadmium from Hot Gas Precipitator dust of Chanderiya

Lead-Zinc Smelter.

Research Enduring

Recovery of metal values from Rampura Agucha Tails.

Recovery of Antimony from Antimony dross of Chanderiya Lead-Zinc

Smelter.

Recovery of Silver from Anode Mud of Chanderiya Lead-Zinc

Smelter.

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FINANCIAL PERFORMANCE IN LAST 5 YEARS

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SOME OF THE CUSTOMERS (Debari Zinc Smelter)

Zinc used in Brass pipes, Brass etc.

1. Gangwal Industries Gwalior2. Agrawal Metal Works (P) Ltd. Rewari3. Alcobex Metal Ltd. Jodhpur

Zinc used in Galvanizing, GI, HR sheets, etc.

1. Steel Co. Stripes Ltd.(Unit No.2) Doraha, Punjab2. National Steel & Agro Ind. Ltd. Indore3. Vardhman Industries Ltd. Rajpura, Punjab4. Jindal Industries Ltd. Hissar5. JSW Steel Ltd. Tarapur6. Laxmi Metal Udyog Delhi7. Multimetals Ltd. Kota8. Swastik Pipes Ltd. New Delhi9. Tata Steel Ltd. Mumbai10. Techman (India)11. Bharat Sanchar Nigam Richhai, Jabalpur

Zinc used in Battaries

1. Nippo Bataries Co. Ltd. Nellore

Zinc used in Insulaters, power transmission

1. Man Structurals (P) Ltd. Jaipur2. Modern Insulation Ltd. Abu Road3. KEC International Ltd. Jaipur4. Agrawal Salt Company Bikaner

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Zinc used for Chemicals

1. Demosha Chemicals (P) Ltd. Bulsar, Gujarat2. Transpek-Silox Industry Ltd. Silvasa

SWOT ANALYSIS

SWOT analysis is a good management approach, which helps the manager to analyze the strength, weakness, opportunity and threats.

STRENGTH:

1. Well set up organization structure: The organization is well defined and this helps in better coordination at various levels of management. Proper authority is delegated at lower levels and responsibility of each personnel is well defined.

2. Human Resource Development: The progressive programs are designed to fill up gaps in the knowledge and skills of employees. Executives are trained through various executive training programs. On the job as well as off the job training programs are conducted for the workers at the shop floor level.

3. Welfare Activities for workers: Various welfare activities are under taken by the company, such as:-

Subsidize canteen facility. Residential facility with subsidized electricity and water supply. Free medical facility for workers at their working place. The company provides free safety equipments security of employees

through PF, gratuity scheme, pension plan and accidental claims.

4. Welfare activities for society: Family planning camps, adult education programs, various events to promote games, sports and cultural activities.

5. Environmental Control Method: The various pollution control measures are operating effectively maintaining ambient air quality and effluent discharge at HZL smelters, mines and townships.

6. Leading producer: HZL is the leading producer of zinc in the country and has the market share of about 70% so he is the market leader.

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WEAKNESS:

1. Extra Manpower: I think that there is extra manpower still even after the privatization of the company and the operating cost can be reduced if we can reduce the unwanted manpower.

OPPORTUNITIES:

1. Increasing Demand: Demand for zinc is increasing day by day but supply of zinc and lead is not fulfilling the requirement.

2. Especially zinc is used for galvanization, paints, pharmaceuticals, automobile etc.

THREATS:

1. Globalization: In the present sense, the entire world is experiencing an explosive growth of global trade.

2. Globalization has provided an opportunity to expand business it has lead to simultaneous increase in international competition.

3. Government Policies: Instability within the country is major threats to all business organization whether it is a public sector or private sector undertaking.

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CONCLUSION

1. As we can see from the above financial statement that the turnover or sales of the company is increasing at increasing rate expect the last 07-08. This shows the company is regularly increasing the production capacity as there is demand in the market.

2. As we have seen above the various uses of zinc in various products the company has covered customers of virtually all kind as we can see from the above customer list.

3. As we have seen from above that there are only two major players of zinc in India i.e. HZL and Binani so there is virtually no competition in the market as the HZL is having all major mines with him.

4. As the sales is increasing every year it shows that increasing demand of zinc in the market.

Suggestions

1. As the demand is more than the supply in the domestic market and nearly 25% of demand is fulfilled by importing it from other countries so, HZL should search more mines and should increase the production as there is still some demand left in the domestic market even though the company is having market share of nearly 70%.

2. As we have seen from the above customer list that most the customers are those which are engaged in galvanizing of steel and having less customer of batteries so, company look more zinc batteries company , zinc die casting companies, zinc sheets manufactures which is used in infrastructure.

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3. Zinc consumption in India is expected to grow at 8%-10% p.a due to the growing market of automotive and industrial batteries from current demand, so company should increase its production capacity to increase in sales and earn more profit.

BIBLIOGRAPHY

Annual Report HZL Zinc News www.crnindia.com www.azobuild.com www.iza.com www.hzlindia.com HZL Debari Zinc Smelter

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http://www.hzlindia.com/

http://www.iza.com/

http://www.azobuild.com/

http://www.crnindia.com/

project hzl 2

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