A project on,“CENTRIFUGE MACHINE FOR

REMOVING EXCESS ZINC AFTER GALVANIZING PROCESS”

ByKansara Nachiket R.

Gujar Sayali R.Mali Chetankumar D.

Bhosale Shital S. Under The Guidance Of

Prof. A. D. Bagawade

INTRODUCTIONCorrosion protection of carbon steel

component is achieved by Metallic coating. Zinc is usually chosen for reason of

economics and reliable.Zinc coating is done by an electroplating

process and by hot dip galvanizing. In hot dip galvanizing Corrosion protection is

proportional to the coating thickness, i.e. the thicker the coating the longer the service life.

What is hot dip galvanizing?

Fig. Galvanizing process

PROBLEM STATEMENT•After the Hot Dip Galvanizing of the Materials like Nuts, Bolts and Washers, zinc gets stuck-up in between their threaded portions.

•Necessity to remove this excess Zinc to achieve better Quality of uniform & smooth coating of the small parts.

•This Extra zinc is presently removed by using Grinders, Flat & Round rough files and by Hammering on it.

To perform above operations following are the Disadvantages.1. Manual Work harmful to the face & eyes of the Operators. 2. Time consuming and reduces the output.3. Reduced the Production and Productivity beyond the Target. 4. Due to extra Coating, Zinc consumption increases.

BASE STAND FLANGE

PARTS

ROTATING CAGE OUTER CONICAL DRUM

BUCKET

OUTER STATIONARY DRUM

ROTATING CAGE

FLANGE

SUPPORTING BEARING

BASE STAND

MOTOR

ARRANGEMENT OF PARTS

ASSEMBLY OF CENTRIFUGAL MACHINE

CENTRIFUGE MACHINE

WITHOUT USING CENTRIFUGAL MACHINE

USING CENTRIFUGAL MACHINE

COMPARISON OF TWO PARTS

BEFORE NOW

EXCESS ZINC COLLECTED AFTER MACHINING

RESULTSSr.

No.

Parameters Foundation

Bolt

1 Black weight of single part (Kg) 0.964

2 Galvanized weight of single part (Kg) 1.02184

3 Total no. of parts in the bucket 731

4 Black weight of all parts (Kg) 704.684

5 Galvanized Weight of all parts (Kg) 746.96

6 Total amount of zinc required for coating of all

parts in Bucket (Kg)

42.276

Sr.

No.

Parameter (For Foundation Bolt) With

Centrifuge

Machine

Without

Centrifuge

Machine

a. Weight of zinc collected after manual

removing of all parts in one bucket

(Kg)

17.61 7.037

b. Cost of zinc collected after manual

removing of all parts in one bucket

(Rs.140 / 1 Kg)

2466 985

c. Weight of zinc collected for 1 ton of

parts (Kg.)

25 10

d. Cost of zinc saved/ ton of parts (Rs.) 3500 1400

e. Cost of zinc required for coating of

1ton of parts

4900 7000

Sr. No.

Parameter Without Centrifuge Machine

With Centrifuge Machine

1 Production/ shift (Kg.) 80 500

2 No. of shifts required/ton 12.5 2

3 Manpower/ shift 4 2

4 Manpower/ton 50 4

5 Manpower cost/ton (Rs.) 12500 1000

Manpower Cost

Total Cost SavedSr.

No.

Parameter Without

Centrifuge

Machine

With

Centrifuge

Machine

1 Cost of zinc required/ ton

of parts (Rs.)

7000 4900

2 Manpower cost/ton (Rs.) 12500 1000

Total Cost (Rs.) 19500 5900

Hence, by using Centrifuge Machine we can save, =19500-5900 =13600 Rs. /ton

COST ESTIMATIONParameter Cost (Rs.)

Raw material cost 26514

Machining cost 3778

Motor cost

Bearings (6206z)

(4 No.s)

16000

1250

Total cost 47542

ADVANTAGESSimple operation Automatic operation Optimum cleaning conditions  Little space requiredNo Harm to face and eyes of the

Operator. Less Time consuming and increases the

output. Improve the Production Quality and

Productivity. Better Quality of uniform & smooth

coating

DisadvantagesCentrifuge Machine can only be used for continuous production.

It is used only for smaller parts like Foundation bolts, Bolts, Nuts, Washers etc.

Manual Loading and unloading.

CONCLUSION Large number of disadvantages with present

system used for removing excess zinc have been obsolete by implementing new centrifuge machine. By using this machine we can obtain better finish and quality of galvanized parts. The use of centrifuge machine can reduce the manpower cost with increase in production rate.

The amount of zinc recovered after a single spin in centrifuge machine is 1.75 % to 2.5% of total amount of zinc required for coating. Thus this recovered zinc can be reuse.

In the industries where continuous production and galvanizing of small is takes place, the centrifuge machine is the better option.

Future ScopeAutomization of Machine

Using of Variable speed motor

Arrangements

THANK YOU!