The present study would not have been the light of the day without the due guidance and cooperation 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:Place:- UDAIPUR
Neeraj Chaudhary
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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 worlds 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 2 nd of February 1989. The industrial upswing that took place in the country during 60s 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 companys 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) 2) 3) 4) 5) 6) Actual production with installed capacity of company. Different uses of Zinc in different industry. Various data relating production and consumption of Zinc. Customer list of Debari Zinc Smelter. Conclusion and suggestion regarding. 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
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ZINC
Zn
General
Name, Symbol, Number Chemical series Group, Period, Block Appearance Atomic mass Electron configuration Electrons per shell zinc, Zn, 30 transition metals 12, 4, d bluish pale gray 65.409(4) g/mol [Ar] 3d10 4s2 2, 8, 18, 2
Physical Properties
Phase Density (near r.t.) Liquid density at m.p. Melting point Boiling point Heat of fusion Heat of vaporization Heat capacity solid 7.14 gcm3 6.57 gcm3 692.68 K (419.53 C, 787.15 F) 1180 K (907 C, 1665 F) 7.32 kJmol1 123.6 kJmol1 (25 C) 25.390 Jmol1K1
Vapor Pressure P/Pa at T/K 1 610 10 670 100 750 1k 852 10 k 990 100 k (1185)
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Atomic properties
Crystal structure Oxidation states Electronegativity Ionization energies (more) Atomic radius Atomic radius (calc.) Covalent radius Van der Waals radius hexagonal 2 (amphoteric oxide) 1.65 (Pauling scale) 1st: 906.4 kJmol1 2nd: 1733.3 kJmol1 3rd: 3833 kJmol1 135 pm 142 pm 131 pm 139 pm
Miscellaneous
Magnetic ordering Electrical resistivity Thermal conductivity Thermal expansion Speed of sound (thin rod) Young's modulus Shear modulus Bulk modulus Poisson ratio Mohs hardness Brinell hardness CAS registry number diamagnetic (20 C) 59.0 nm (300 K) 116 Wm1K1 (25 C) 30.2 mm1K1 (r.t.) (rolled) 3850 ms1 108 GPa 43 GPa 70 GPa 0.25 2.5 412 MPa 7440-66-6
Notable Isotopes of Zinc iso 64Zn 65Zn 66Zn 67Zn 68Zn 69Zn 70Zn NA 48.6% syn 27.9% 4.1% 18.8% syn 0.6% half-life DM 1.1155 DE (MeV) DP 65Cu Zn is stable with 34 neutrons 244.26 d
Zn is stable with 36 neutrons Zn is stable with 37 neutrons Zn is stable with 38 neutrons 56.4 min 0.906 69Ga Zn is stable with 40 neutrons
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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 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 worlds 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 magmatichydrothermal 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 earths 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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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.
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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 add an 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 13.9 million 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 due to 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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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
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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.
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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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.
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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 Leclanch) 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 alpharays, which render it luminescent. ZnS and the selenide ZnSe are used in infrared optics.
Zinc salts have various applications: zinc chloride in the textile industry, in the manufacturing of Leclanch 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.
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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. 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.
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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 countrys 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. 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 coatings 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. 23 | P a g e
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.
2.1.2. Cathodic Protection: Another outstanding protection mechanism is zincs 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.
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When painted zinc-coated steel is scratched, zinc protects both the underlying steel from corrosion and the overlying paint coat from lifting.
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, zincs high corrosion resistance prevents undercutting of the paint film. Even if the coating damage does reach the steel base, zincs cathodic action will prevent the steel from corroding. Zincs 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 m galvanized coating plus a 100 m 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 m and best quality painting method is continuous coil coating or pre-painting. This allows for exact preparation of the ga prior to coil coating. Painted galvanized sheet is roll-formed to give profiles specified by the customer. Recent advanc technology and paint systems enable pre-painted galvanized sheet to be roll-formed with striking patterns, allowin roofing and cladding possibilities for industrial, commercial and residential buildings. For example, roll forming and s 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 g Todays automobiles have a perfect body finish that combines a high degree of aesthetic standards of corrosion protection. Roll formed pre-painted sheet for building, cladding and three main assets - the aesthetic appearance of sharp profile, long life and favourable econom
Roll forming of pre-painted sheet gives a lower cost than painting after forming. Dom combine severe forming with guaranteed corrosion protection to meet the requirements of modern design. Steel sh 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 galvanized steel sheet. The table below lists some of the more popular coating weights available in each product standa 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 manufac galvanized sheet is a major constituent in the 50 million vehicles and over 40 million appliances produced each ye countless commercial and industrial buildings. A growing market is galvanized steel framing and roofing for residentia
Today, there are over 550 continuous galvanizing lines worldwide and additional capacity is planned in response to gro
Zinc-coated steel resists decay, corrosion, termites, fire, wind, floods and earthquakes better than any other construct this reason, it is being used more and more in commercial and residential construction.
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The growth in auto industry use of zinc-coated steel sheet Source: IZA-Europe
3.5. Economics: Zinc-coated steel sheet offers a unique combination of strength, durability, formability, recycl Recyclability is a key selection criteria for specifiers. The existence of cost-effective recycling routes contributes favor cost of zinc-coated steel products.
The use of galvanized sheet for automotive body panels allows todays automakers to guarantee up to 12 years corr while adding only a fraction of a percent to the cost of the vehicle. The cost-benefit ratio represents outstanding value f The same applies to building panels - galvanized coil coated products are now available with up to 50 year performanc improved performance and added value generated by zinc coated steel sheet is vastly superior to the small additional Durability, aesthetics, longterm stability of surface appearance and low maintenance are all significant advantages for t
In the construction industry, galvanized steel decking combined with high-speed concrete pouring allows faster cons lowering construction costs.
Commercial and industrial washing machines can operate every day around the clock thanks to galvanized steel sheet c 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 nee 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 cases, however, these premium products give higher performance. The extra cost involved is small when compared to 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 coatings help expand the markets for steel.
3.6. The Process: Continuous galvanized steel is made under precise, factory-controlled conditions during which flat are upgraded to high-quality, zinc-coated steel using high-speed continuous lines that control not only the coating qu 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 u through cleaning and annealing sections before entering a molten zinc bath at speeds up t minute (650 feet/minute). As the steel exits the molten zinc bath, gas "knives" wipe off th from the steel sheet to control coating thickness. The steel strip then undergoes a series chemical treatments. Depending on customer requirements, the coated sheet steel can be and recoiled, and cut to length and palletized before shipment to the fabricator. All galvan metallurgically bonded to the steel they protect. This ensures coating adhesion - critical fo 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 process. The major use of electrogalvanized coatings is autobody outer panels, although structural components such as inner panels, doors, housings and appliances are also pro material. Continuous Hot Dip Galvanizing Line Courtesy 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 Furnace - 8. Radiant Tube Furnace - 9. Gas Jet Cooling - 10. Controlled Cooling - 11. Zinc Pot - 12. Air/Nitrog Galvannealing Furnace - 14. Tower Roll Clean - 15. - Quench Tank - 16. Water Cooling Dryer - 17. Coating We Temper Rolling -19. Tension Leveller - 20. Skinpass Mill Dryer - 21. Delivery Looping Tower - 21. Electrostatic O 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, AfterFabrication 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 60-70m 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 33 | P a g e
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 coatings can be applied at high thickness (100200 m) 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 380C, 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 34 | P a g e
many years before recycling. It is only recently that some of the lower life-span galvanized products, 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)
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 Indias stake (26%) including management control to Sterlite and pursuant to the regulations of SEBI Regulations 1997 acquired additional 20% of shares from public. 36 | P a g e
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
Refined zinc production capacity 669,000 tonnes per annum Refined lead production capacity 85,000 tonnes per annum
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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
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OPERATIONS
MINING
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Certifications
Certifications
SMELTING
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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.
Hydrometallurgical Zinc Smelter Hydro I Commissioned in 2005 Roast Leach Electrowinning Technology with Lead Silver Residue Recovery 210,000 tonnes per annum of Zinc
Hydrometallurgical Zinc Smelter Hydro II Commissioned in 2007 Roast Leach Electrowinning Technology with Conversion Process 210,000 tonnes per annum of Zinc Commissioned in 2006 TSL Technology from Ausmelt-Australia Cansolv Technology for Sulphur Recovery 50,000 tonnes per annum of Lead Commissioned in 2005 Built by BHEL 2 x 77 MW Commissioned in 2007 Built by BHEL 80 MW Certification ISO 9001:2000, ISO 14001:2004, OHSAS 18001:1999
Lead Smelter
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Highlights
Largest single location Zinc-Lead Smelter Complex in the World Worlds 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) Lead Cadmium Silver Sulphuric Acid - Slabs (25 kgs)
- Slabs
(25 kgs)
Commissioned in 1968 Roast Leach Electrowining Technology with Conversion Process Gone through a series of debotlenecking 88,000 tonnes per annum of Zinc 29 MW DG Set BEST4 Certified Integrated Systems ISO 9001:2000, ISO 14001:2004, OHSAS 18001:1999, SA 8000:2001
Highlights
Jumbo (600 kgs) Cadmium Sulphuric Acid - Pencils (150 gms) - + 98% concentration
17 km from Vishakapatnam, Andhra Pradesh, India Commissioned in 1977 Roast Leach Electrowining Technology with Conversion Process Gone through a series of debotlenecking 56,000 tonnes per annum of Zinc BEST4 Certified Integrated Systems ISO 9001:2000, ISO 14001:2004, OHSAS 18001:1999, SA 8000:2001
Certifications
Highlights
Products Range High Grade Zinc (HG) - Slabs (25 kgs) Cadmium Sulphuric Acid - Pencils (150 gms) - + 98% concentration
Objectives
1977 Located at Debari, 14 km east of Udaipur (Rajasthan) 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 Establish Companys 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 Laminar flow work-station, Autoclave, Incubators (Stationary and shaking), Cooling centrifuge (Normal and high speed cooling), Bioleaching Reactors, Bioleaching columns for bench scale testing.
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.
Zinc used in Brass pipes, Brass etc. 1. Gangwal Industries 2. Agrawal Metal Works (P) Ltd. 3. Alcobex Metal Ltd. Gwalior Rewari Jodhpur
Zinc used in Galvanizing, GI, HR sheets, etc. 1. Steel Co. Stripes Ltd.(Unit No.2) 2. National Steel & Agro Ind. Ltd. 3. Vardhman Industries Ltd. 4. Jindal Industries Ltd. 5. JSW Steel Ltd. 6. Laxmi Metal Udyog 7. Multimetals Ltd. 8. Swastik Pipes Ltd. 9. Tata Steel Ltd. 10. Techman (India) 11. Bharat Sanchar Nigam Richhai, Jabalpur Doraha, Punjab Indore Rajpura, Punjab Hissar Tarapur Delhi Kota New Delhi Mumbai
Zinc used in Insulaters, power transmission 1. Man Structurals (P) Ltd. 2. Modern Insulation Ltd. 3. KEC International Ltd. 4. Agrawal Salt Company Jaipur Abu Road Jaipur Bikaner
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Zinc used for Chemicals 1. Demosha Chemicals (P) Ltd. 2. Transpek-Silox Industry Ltd. Bulsar, Gujarat 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.
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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.
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.
THREATS:
1. Globalization: 50 | P a g e
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.
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.
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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.
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
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