The document describes the various steel treatment and painting processes used on Atlas Copco generators and light towers to protect them from corrosion when exposed to outdoor environments. Different components receive different treatments based on their exposure and importance. All steel components receive a galvanization treatment before further treatments and painting. The canopy receives powder coating, while critical components and the base frame undergo nitrogen laser cutting and cataphoresis before final painting. These treatments help provide long-term corrosion protection and extend the life of components.
When repairing or re-lining furnace stacks, installation time and the selection of suitable material are decisive criteria for construction site planning.
Qualified consultation by our experienced employees enables the customer to find the best solution for the respective lining requirements from the wide range of material groups. Hereby, the customer's needs and the task on hand are always the central issues: Minimum costs, minimum time, and maximum quality regarding input of labour and product.
The new development: Hybrid technology With the development of REFRACAST®️ Hybrid castables, Refratechnik Steel has optimized the technology of Sol-Gel bonded, cement-free castables even further.
Refractory Product Line | Optimum Solutions for Cement PlantsRefratechnik Group
To meet the globally increasing demand for cement, energy saving firing systems with high specific output have been developed in the industrialized countries and introduced throughout the world. One of the primary results of these developments is the precalciner kiln with a short rotary kiln
section.
As each kiln is unique, appropriate refractories are a major factor in terms of service life.
REFRAWIRE® A new Technology for Prefabricated ComponentsRefratechnik Group
In applications subjected to fast temperature variations, severe abrasion, and high mechanical loads, standard concretes or refractory bricks are not always able to withstand these loads. Now, REFRAWIRE®, the latest generation of our prefabricated components is the ideal solution. Prefabricated REFRAWIRE® components were developed specifically to protect equipment linings from thermal shocks and mechanical influences.
Refratechnik aimed at developing a range of refractory concretes that are insensitive to rapid heating.
The result of our research and development work is the Nanobond technology.
Perfect Insulating Materials for the Steel Industry.
For more than 40 years Refratechnik has been developing products with this natural raw material. With the foundation of Refratechnik Casting in 1997 a re-orientation of Refratechnik’s activities, in this field, took place.
The Casting experts have 25 years of experience in the production and application of biogenic silicas. This know-how has helped put Refratechnik Casting into a commanding position.
Refratechnik Casting develops, produces, and supplies highgrade process materials for steel production.
The Casting experts have 25 years of experience in the production
and application of biogenic silicas. This know-how has helped put
Refratechnik Casting into a commanding position.
Saving energy with insulation.
A decisive role in modern process guidance for reducing energy consumption is played by the insulating materials used in every refractory lining.
As invisible but important components in every refractory lining, high-temperature insulating materials reduce the lining's thermal profile and thereby protect the furnace's steel shell from excesive heating effects.
With our newly developed PROLITE®, we offer our customers a highly insulating material made of biogenic silicilic acid, which combines these factors in a sustainable way.
When repairing or re-lining furnace stacks, installation time and the selection of suitable material are decisive criteria for construction site planning.
Qualified consultation by our experienced employees enables the customer to find the best solution for the respective lining requirements from the wide range of material groups. Hereby, the customer's needs and the task on hand are always the central issues: Minimum costs, minimum time, and maximum quality regarding input of labour and product.
The new development: Hybrid technology With the development of REFRACAST®️ Hybrid castables, Refratechnik Steel has optimized the technology of Sol-Gel bonded, cement-free castables even further.
Refractory Product Line | Optimum Solutions for Cement PlantsRefratechnik Group
To meet the globally increasing demand for cement, energy saving firing systems with high specific output have been developed in the industrialized countries and introduced throughout the world. One of the primary results of these developments is the precalciner kiln with a short rotary kiln
section.
As each kiln is unique, appropriate refractories are a major factor in terms of service life.
REFRAWIRE® A new Technology for Prefabricated ComponentsRefratechnik Group
In applications subjected to fast temperature variations, severe abrasion, and high mechanical loads, standard concretes or refractory bricks are not always able to withstand these loads. Now, REFRAWIRE®, the latest generation of our prefabricated components is the ideal solution. Prefabricated REFRAWIRE® components were developed specifically to protect equipment linings from thermal shocks and mechanical influences.
Refratechnik aimed at developing a range of refractory concretes that are insensitive to rapid heating.
The result of our research and development work is the Nanobond technology.
Perfect Insulating Materials for the Steel Industry.
For more than 40 years Refratechnik has been developing products with this natural raw material. With the foundation of Refratechnik Casting in 1997 a re-orientation of Refratechnik’s activities, in this field, took place.
The Casting experts have 25 years of experience in the production and application of biogenic silicas. This know-how has helped put Refratechnik Casting into a commanding position.
Refratechnik Casting develops, produces, and supplies highgrade process materials for steel production.
The Casting experts have 25 years of experience in the production
and application of biogenic silicas. This know-how has helped put
Refratechnik Casting into a commanding position.
Saving energy with insulation.
A decisive role in modern process guidance for reducing energy consumption is played by the insulating materials used in every refractory lining.
As invisible but important components in every refractory lining, high-temperature insulating materials reduce the lining's thermal profile and thereby protect the furnace's steel shell from excesive heating effects.
With our newly developed PROLITE®, we offer our customers a highly insulating material made of biogenic silicilic acid, which combines these factors in a sustainable way.
Longer running times and shorter down-times for repairs or new linings mean that specific solutions are more and more frequently required for the refractory lining of blast furnace runners.
This is why we provide concepts tailored to suit the requirements of any particular section of runner and to take account of latest developments.
REFRATHERM® | Refractory Insulating Products for the Cement and Lime IndustryRefratechnik Group
The use of refractory insulating products is absolutely indispensable for industrial high temperature processes that are economical and ecological.
Refratechnik Cement develops and constructs innovative refractory lining systems for the cement and lime industry, putting special emphasis on the heat-insulating properties.
Refractory insulating materials produced by Refratechnik Cement are amongst others supplied as plates, blankets, cords, wool or paper to cope with all demands that are made on advanced, high-grade refractory constructions.
Flexible, durable, individual.
Nowadays, and apart from the actual tasks, hot metal transport vessels are sometimes used to carry out metallurgical processing steps that go far beyond the transport from blast furnace to steel plant, and for filling the converters.
We have taken this into account, and for all standard lining concepts we supply bauxite, calcined or carbon-bonded andalusite and – to an increasing degree – high-grade carbon-bonded bauxite with SiC additive. And of course, refractory castables for pouring areas and repair are also included in the product range.
The insulating covering agent for ingots.
NERMAT® AF's excellent insulating properties guarantee a slow solidification of the ingot top and a higher amount of impurities can be eliminated from the steel.
Intelligent refractory technology for the primary aluminium industryRefratechnik Group
With decades of experience in refractory technology for the aluminium industry, Refratechnik is one of the world's most innovative companies in this field.
For your activities in the aluminium industry, we offer comprehensive and customized refractory solutions. Our company's aim is to respond to the significantly increased demands made on refractory materials during recent years, by developing new and high-grade products.
The gas purging of steel or metal melts is an important part of modern secondary metallurgy. Added alloying agents are dissolved more rapidly and better distributed by the injection of inert gases (argon and nitrogen) through a purging plug in the bottom or the wall of the casting ladle. In addition, homogenisation of the bath temperature is improved by gas purging.
Low-Alpha Technology: The innovative refractory solution for steel devices su...Refratechnik Group
In modern steel production, plant reliability is playing an increasingly important role. Innovative and comprehensive refractory concepts are decisive when it comes to optimizing steel production processes in terms of performance and costs. In close cooperation with our customers, we develop, test, and supply perfect solutions.
REFRATHERM® Eco High-End Insulation for the Tunnel Kiln CarRefratechnik Group
For more than 50 years, Refratechnik has carried out research and development in the field of biogenic silica. First experiences in thermal processes have led to a continuous expansion of know-how and our own production of the material. The thermal insulating properties have been further developed and specialised for today’s applications.
The development of the special insulation REFRATHERM® Eco for use in the heavy clay industry opens up convincing new applications.
Intelligent Refractory Technology for the Aluminium Industry. Casthouse. Refratechnik Group
High-performance products and intelligent refractory concepts.
Refratechnik is one of the most important companies in the refractory industry and, with its shaped and unshaped products, a global partner of the cement, steel and aluminium industry.
Monolithic products, soon to include pre-shaped products (bricks and prefabricated components), are playing an increasingly important part in Refratechnik's service spectrum, enjoying a notable increase in sales and commanding the highest of respect on the market.
For all areas of production in the steel industry where there is a demand for refractory technology, Refratechnik Steel offer concepts and solutions which are adapted fundamentally to our customer`s individual situation. In this endeavour, we are able to draw on our extensive range of refractory products.
CERAMAC® – the smart solution for the longest service life without emissions.
In the beginning, the original goal in developing CERAMAC® was to make it easier to meet environmental regulations and to improve the service life. In the lining concepts, the pre-fired material reduces the smoke emissions and the release of particles while also improving mechanical properties.
The fast and lasting solution for hot and cold repairs.
For conventional hot or cold repairs, e.g. on casting ladles and covers, a time of roughly one day is required, plus about 1 to 1,2 tons of repair material.
We have developed a monolithic line of products that cuts the repair times and improves the working conditions: REFRASPRAY®.
Lining Concepts for the Lead Industry - Short Rotary FurnacesRefratechnik Group
The processes to produce non-ferrous metals are as varied and complex as the equipment required for the purpose.
For new linings, repair, and servicing of short rotary furnaces, Refratechnik Steel offers high-fired magnesia chromite products with low porosity and low SiO2 contents.
High performance magnesia-spinel brick for transition zones in cement rotary kilns.
TOPMAG® TR – a benchmarking brick grade for transition zones in cement rotary kilns with properties for longer life time. TOPMAG® TR has been reinforced by utilizing high grade fusedspinel, which greatly enhances the thermochemical resistance. Specifically adjusted spinel content provides additional improved structural flexibility.
Intelligent solutions in the overall refractory concept.
Refratechnik has developed optimized solutions for the wide range of demands placed on prefabricated refractories in all industries. Based on our long-term experience in manufacturing high-quality prefabricated refractories, new methods have been found for drying, combustion, and compacting technology.
REPROMAT - The Perfect Slag Conditioner for Steel ProductionRefratechnik Group
The use of reactive MgO has become established as an excellent solution for minimizing the attack on the refractory material by aggressive slags, and to obtain an optimum degree of saturation range in the slag. For this purpose, and as specialists for refractory products and process materials, Refratechnik has developed the special product REPROMAT.
Increasing die life, reducing rejections by the use of japanese cold welding ...Srikar Shenoy
1. Die, mould and tool wear are major reasons for production downtime and increased costs in most industries. Apart from using suitable alloy steels for making dies, a few effective treatments like nitriding, PVD & CVD can be administered to increase die life. Such treatments are not feasible for all metal forming units. Carbide coating to protect only the wear-prone areas of dies using Japanese cold-welding technology is a practical and economical technique that has proven to increase die life. This technique, though similar to welding, does not need pre and post-weld heat treatment and skilled labour. The process does not emit smoke. It can also be carried out on the die or tool without unloading it from the casting press or such equipment, without need of a weld shop.
2. Die spray units are used to effectively spray lubricant on the dies. During the pressure die casting process, it is mandatory to keep die and plunger well lubricated. Die protective coating cum lubricant is used to achieve these objectives. Until recently, pressure feed tanks have been used to spray-lubricate dies. However, these conventional pressure-feed tanks are proving to be a hazard on the shop floor. Pressurised equipments on shop floor always pose a risk of explosion. They also cause production downtime during re-filling. Better alternatives are now available for dispensing die lubricants.
Longer running times and shorter down-times for repairs or new linings mean that specific solutions are more and more frequently required for the refractory lining of blast furnace runners.
This is why we provide concepts tailored to suit the requirements of any particular section of runner and to take account of latest developments.
REFRATHERM® | Refractory Insulating Products for the Cement and Lime IndustryRefratechnik Group
The use of refractory insulating products is absolutely indispensable for industrial high temperature processes that are economical and ecological.
Refratechnik Cement develops and constructs innovative refractory lining systems for the cement and lime industry, putting special emphasis on the heat-insulating properties.
Refractory insulating materials produced by Refratechnik Cement are amongst others supplied as plates, blankets, cords, wool or paper to cope with all demands that are made on advanced, high-grade refractory constructions.
Flexible, durable, individual.
Nowadays, and apart from the actual tasks, hot metal transport vessels are sometimes used to carry out metallurgical processing steps that go far beyond the transport from blast furnace to steel plant, and for filling the converters.
We have taken this into account, and for all standard lining concepts we supply bauxite, calcined or carbon-bonded andalusite and – to an increasing degree – high-grade carbon-bonded bauxite with SiC additive. And of course, refractory castables for pouring areas and repair are also included in the product range.
The insulating covering agent for ingots.
NERMAT® AF's excellent insulating properties guarantee a slow solidification of the ingot top and a higher amount of impurities can be eliminated from the steel.
Intelligent refractory technology for the primary aluminium industryRefratechnik Group
With decades of experience in refractory technology for the aluminium industry, Refratechnik is one of the world's most innovative companies in this field.
For your activities in the aluminium industry, we offer comprehensive and customized refractory solutions. Our company's aim is to respond to the significantly increased demands made on refractory materials during recent years, by developing new and high-grade products.
The gas purging of steel or metal melts is an important part of modern secondary metallurgy. Added alloying agents are dissolved more rapidly and better distributed by the injection of inert gases (argon and nitrogen) through a purging plug in the bottom or the wall of the casting ladle. In addition, homogenisation of the bath temperature is improved by gas purging.
Low-Alpha Technology: The innovative refractory solution for steel devices su...Refratechnik Group
In modern steel production, plant reliability is playing an increasingly important role. Innovative and comprehensive refractory concepts are decisive when it comes to optimizing steel production processes in terms of performance and costs. In close cooperation with our customers, we develop, test, and supply perfect solutions.
REFRATHERM® Eco High-End Insulation for the Tunnel Kiln CarRefratechnik Group
For more than 50 years, Refratechnik has carried out research and development in the field of biogenic silica. First experiences in thermal processes have led to a continuous expansion of know-how and our own production of the material. The thermal insulating properties have been further developed and specialised for today’s applications.
The development of the special insulation REFRATHERM® Eco for use in the heavy clay industry opens up convincing new applications.
Intelligent Refractory Technology for the Aluminium Industry. Casthouse. Refratechnik Group
High-performance products and intelligent refractory concepts.
Refratechnik is one of the most important companies in the refractory industry and, with its shaped and unshaped products, a global partner of the cement, steel and aluminium industry.
Monolithic products, soon to include pre-shaped products (bricks and prefabricated components), are playing an increasingly important part in Refratechnik's service spectrum, enjoying a notable increase in sales and commanding the highest of respect on the market.
For all areas of production in the steel industry where there is a demand for refractory technology, Refratechnik Steel offer concepts and solutions which are adapted fundamentally to our customer`s individual situation. In this endeavour, we are able to draw on our extensive range of refractory products.
CERAMAC® – the smart solution for the longest service life without emissions.
In the beginning, the original goal in developing CERAMAC® was to make it easier to meet environmental regulations and to improve the service life. In the lining concepts, the pre-fired material reduces the smoke emissions and the release of particles while also improving mechanical properties.
The fast and lasting solution for hot and cold repairs.
For conventional hot or cold repairs, e.g. on casting ladles and covers, a time of roughly one day is required, plus about 1 to 1,2 tons of repair material.
We have developed a monolithic line of products that cuts the repair times and improves the working conditions: REFRASPRAY®.
Lining Concepts for the Lead Industry - Short Rotary FurnacesRefratechnik Group
The processes to produce non-ferrous metals are as varied and complex as the equipment required for the purpose.
For new linings, repair, and servicing of short rotary furnaces, Refratechnik Steel offers high-fired magnesia chromite products with low porosity and low SiO2 contents.
High performance magnesia-spinel brick for transition zones in cement rotary kilns.
TOPMAG® TR – a benchmarking brick grade for transition zones in cement rotary kilns with properties for longer life time. TOPMAG® TR has been reinforced by utilizing high grade fusedspinel, which greatly enhances the thermochemical resistance. Specifically adjusted spinel content provides additional improved structural flexibility.
Intelligent solutions in the overall refractory concept.
Refratechnik has developed optimized solutions for the wide range of demands placed on prefabricated refractories in all industries. Based on our long-term experience in manufacturing high-quality prefabricated refractories, new methods have been found for drying, combustion, and compacting technology.
REPROMAT - The Perfect Slag Conditioner for Steel ProductionRefratechnik Group
The use of reactive MgO has become established as an excellent solution for minimizing the attack on the refractory material by aggressive slags, and to obtain an optimum degree of saturation range in the slag. For this purpose, and as specialists for refractory products and process materials, Refratechnik has developed the special product REPROMAT.
Increasing die life, reducing rejections by the use of japanese cold welding ...Srikar Shenoy
1. Die, mould and tool wear are major reasons for production downtime and increased costs in most industries. Apart from using suitable alloy steels for making dies, a few effective treatments like nitriding, PVD & CVD can be administered to increase die life. Such treatments are not feasible for all metal forming units. Carbide coating to protect only the wear-prone areas of dies using Japanese cold-welding technology is a practical and economical technique that has proven to increase die life. This technique, though similar to welding, does not need pre and post-weld heat treatment and skilled labour. The process does not emit smoke. It can also be carried out on the die or tool without unloading it from the casting press or such equipment, without need of a weld shop.
2. Die spray units are used to effectively spray lubricant on the dies. During the pressure die casting process, it is mandatory to keep die and plunger well lubricated. Die protective coating cum lubricant is used to achieve these objectives. Until recently, pressure feed tanks have been used to spray-lubricate dies. However, these conventional pressure-feed tanks are proving to be a hazard on the shop floor. Pressurised equipments on shop floor always pose a risk of explosion. They also cause production downtime during re-filling. Better alternatives are now available for dispensing die lubricants.
TALAT Lecture 5301: The Surface Treatment and Coil Coating of AluminiumCORE-Materials
This lecture describes the continuous coil coating processes for aluminium in sufficient detail in order to understand the industrial coating technology and its application potential. General background in materials engineering and familiarity with the subject matter covered in TALAT This lectures 5100 and 5200 is assumed.
The Advantages of Using Extrusions to Solve Thermal Management ChallengesDesign World
Driven by the need to improve fuel economy and reduce carbon emissions, the automotive industry has focused on developing Electric-drive vehicles (EDVs) as well as the lightweighting of vehicles. This increasing trend has been supported by major manufacturers such as Ford and Tesla. However, with any change in technology new challenges develop. Thermal Management of these vehicles is a large challenge, along with the need to structurally hold the components in place.
A Technical Data Sheet covering our architectural anti slip stair tread nosings showing dimensions available and options such as glow strips for wayfinding.
Alpha Metal Finishing provided a hardcoat anodizing lunch and learn presentation in May 2014. Special thanks to Rob Pawson from Reliant Aluminum Products for assisting us.
ProCoat Industrial Corrosion Protection. Rebuilding and refurbishing. Steel, Power, Cement, Marine, waste water Treatment, Paper, Process, Soda Ash, FGD Systems, Tank, Electricity, corrosion, Erosion, Cavitation, pitting, Acid protections, chemical protection, Transmission and many more industries.
Romotas was founded in 1973 by Leon Terlecki.
Romotas has been a name synonymous with quality, integrity & innovation at every stage of our development. We continuously invest in new technologies whilst instilling the values and work ethics that have forged this company into the surface engineering powerhouse that it is.
Thermal Hardfacing Solution
For construction professionals and sales personnel.
The material will take you through the basics of raw materials and coatings as well as describes how to use them in different applications. After studying the material you will:
* Know the basics of raw materials and coatings
* Know the newest products in coatings
* Get introduced to how different coatings and steel grades are used in construction applications
* Know some technical performance of the coatings
* Get a deeper overview of the two newest coating options
* Get some important tips maintenance-wise
Read more about steel coatings:
ruukki.com/colourcoatedsteels
ruukki.com/metalcoatedsteels
Overview of the fundamental roles in Hydropower generation and the components involved in wider Electrical Engineering.
This paper presents the design and construction of hydroelectric dams from the hydrologist’s survey of the valley before construction, all aspects and involved disciplines, fluid dynamics, structural engineering, generation and mains frequency regulation to the very transmission of power through the network in the United Kingdom.
Author: Robbie Edward Sayers
Collaborators and co editors: Charlie Sims and Connor Healey.
(C) 2024 Robbie E. Sayers
Automobile Management System Project Report.pdfKamal Acharya
The proposed project is developed to manage the automobile in the automobile dealer company. The main module in this project is login, automobile management, customer management, sales, complaints and reports. The first module is the login. The automobile showroom owner should login to the project for usage. The username and password are verified and if it is correct, next form opens. If the username and password are not correct, it shows the error message.
When a customer search for a automobile, if the automobile is available, they will be taken to a page that shows the details of the automobile including automobile name, automobile ID, quantity, price etc. “Automobile Management System” is useful for maintaining automobiles, customers effectively and hence helps for establishing good relation between customer and automobile organization. It contains various customized modules for effectively maintaining automobiles and stock information accurately and safely.
When the automobile is sold to the customer, stock will be reduced automatically. When a new purchase is made, stock will be increased automatically. While selecting automobiles for sale, the proposed software will automatically check for total number of available stock of that particular item, if the total stock of that particular item is less than 5, software will notify the user to purchase the particular item.
Also when the user tries to sale items which are not in stock, the system will prompt the user that the stock is not enough. Customers of this system can search for a automobile; can purchase a automobile easily by selecting fast. On the other hand the stock of automobiles can be maintained perfectly by the automobile shop manager overcoming the drawbacks of existing system.
Immunizing Image Classifiers Against Localized Adversary Attacksgerogepatton
This paper addresses the vulnerability of deep learning models, particularly convolutional neural networks
(CNN)s, to adversarial attacks and presents a proactive training technique designed to counter them. We
introduce a novel volumization algorithm, which transforms 2D images into 3D volumetric representations.
When combined with 3D convolution and deep curriculum learning optimization (CLO), itsignificantly improves
the immunity of models against localized universal attacks by up to 40%. We evaluate our proposed approach
using contemporary CNN architectures and the modified Canadian Institute for Advanced Research (CIFAR-10
and CIFAR-100) and ImageNet Large Scale Visual Recognition Challenge (ILSVRC12) datasets, showcasing
accuracy improvements over previous techniques. The results indicate that the combination of the volumetric
input and curriculum learning holds significant promise for mitigating adversarial attacks without necessitating
adversary training.
TECHNICAL TRAINING MANUAL GENERAL FAMILIARIZATION COURSEDuvanRamosGarzon1
AIRCRAFT GENERAL
The Single Aisle is the most advanced family aircraft in service today, with fly-by-wire flight controls.
The A318, A319, A320 and A321 are twin-engine subsonic medium range aircraft.
The family offers a choice of engines
Quality defects in TMT Bars, Possible causes and Potential Solutions.PrashantGoswami42
Maintaining high-quality standards in the production of TMT bars is crucial for ensuring structural integrity in construction. Addressing common defects through careful monitoring, standardized processes, and advanced technology can significantly improve the quality of TMT bars. Continuous training and adherence to quality control measures will also play a pivotal role in minimizing these defects.
Cosmetic shop management system project report.pdfKamal Acharya
Buying new cosmetic products is difficult. It can even be scary for those who have sensitive skin and are prone to skin trouble. The information needed to alleviate this problem is on the back of each product, but it's thought to interpret those ingredient lists unless you have a background in chemistry.
Instead of buying and hoping for the best, we can use data science to help us predict which products may be good fits for us. It includes various function programs to do the above mentioned tasks.
Data file handling has been effectively used in the program.
The automated cosmetic shop management system should deal with the automation of general workflow and administration process of the shop. The main processes of the system focus on customer's request where the system is able to search the most appropriate products and deliver it to the customers. It should help the employees to quickly identify the list of cosmetic product that have reached the minimum quantity and also keep a track of expired date for each cosmetic product. It should help the employees to find the rack number in which the product is placed.It is also Faster and more efficient way.
Student information management system project report ii.pdfKamal Acharya
Our project explains about the student management. This project mainly explains the various actions related to student details. This project shows some ease in adding, editing and deleting the student details. It also provides a less time consuming process for viewing, adding, editing and deleting the marks of the students.
NO1 Uk best vashikaran specialist in delhi vashikaran baba near me online vas...Amil Baba Dawood bangali
Contact with Dawood Bhai Just call on +92322-6382012 and we'll help you. We'll solve all your problems within 12 to 24 hours and with 101% guarantee and with astrology systematic. If you want to take any personal or professional advice then also you can call us on +92322-6382012 , ONLINE LOVE PROBLEM & Other all types of Daily Life Problem's.Then CALL or WHATSAPP us on +92322-6382012 and Get all these problems solutions here by Amil Baba DAWOOD BANGALI
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Water scarcity is the lack of fresh water resources to meet the standard water demand. There are two type of water scarcity. One is physical. The other is economic water scarcity.
Industrial Training at Shahjalal Fertilizer Company Limited (SFCL)MdTanvirMahtab2
This presentation is about the working procedure of Shahjalal Fertilizer Company Limited (SFCL). A Govt. owned Company of Bangladesh Chemical Industries Corporation under Ministry of Industries.
1. STEEL TREATMENTS
AND PAINTING
PROCESS
In this document, we will explain detailed the process and treatments that all
Atlas Copco product ranges, manufactured in our Product Company located
in Zaragoza (Spain) suffer in order to achieve the best performance avoiding
corrosion over the years.
Written by: Bárbara Gregorio
Technical sales support for generators and light towers
PN - 2960 0400 00
2. INTRODUCTION
Generators and light towers spend much
of their working lives outside exposed to
the elements.
The environments can be tough: rain,
seawater, wind, ultraviolet radiation,
natural and industrial dust, sand and mud.
For obvious reasons, these vital machines
must be kept in constant working order
and therefore need protection from the
elements and be secure from damage.
This is why a well- designed, well
produced and long-lasting canopy is of
the utmost importance.
Steel tends to be the standard material on
all middle and large machines. It is
resistant, it is strong and it can withstand
the heat and vibration the machines
produce, and it is able to protect the inner
workings of the machine also.
MAIN GOAL:
AVOID CORROSION
One of the only disadvantages to be
overcome with canopies made of steel is
corrosion. Steel oxidizes on contact with
the oxygen dissolved in water, and the
presence of salt or heat can accelerate this
process.
The corrosion of steel is an
electrochemical process requiring oxygen
in its dissolved (aqueous) form, and the
chemical formula looks like this:
4Fe + 3O2 2Fe O2 (iron oxide or
rust)
It is the loss of electrons from the steel
and the gain of electrons by OH-
(hydroxide ions) created in the process
that drives the reaction.
To inhibit corrosion, the steel plates used
in canopy construction are protected by
Galva-steel process.
3. STEEL PRE-TREATMENT: GALVA-STEEL
In the continuous hot-dipped galvanization process that produces Galva-steel, the steel
sheets are submersed in molten zinc and a chemical reaction takes place in which the zinc
is permanently bonded to the steel.
The external layer is pure zinc, but successive layers are a mixture of zinc and iron, until
the interior, which is pure steel. This layer can reach up to 25µm thickness.
External aspect sample Under microscope
Pretreatment for normal steel plate (> 3mm):
Cleaning: removing of dust, rust, chips. If there is rust, sandblasting is needed
Warm alcalic degreasing
Zn phosphation
Cr-3 passivation
Drying in order to remove all water between welded plates.
The result of this process means there is a considerable barrier between the steel plate and
air ensuring that if the painted surface is compromised, there will still be, during a
substantial time-period, no corrosion of the steel and only the presence of white zinc
oxide. The corrosion of the steel and production of red iron oxide will be greatly
inhibited.
4. The high levels of zinc present in Galva-steel make it more resistant to standard welding
processes (zinc splatters and tends to burn producing toxic zinc oxide vapour).
Advantages of Galva-Steel canopies:
• Galvanized steel (Galva-Steel) offers very high resistance to corrosion and is the first
choice when using any sheet metal that must be almost continually exposed to the
elements.
• Besides being affordable, durable and effective, this metal is also popular because it can
be recycled and reused multiple times.
All the canopies of our generators and light towers are galvanized and also some critical
parts as: mast support, exhaust pipe, base frame supports…
STEEL CUTTING PROCESS: N2 LASER
This is a high-pressure laser cutting system, used in all our steel pieces in order to achieve
excellent quality.
Oxygen laser burns the material accelerating the oxidation or corrosion status, but
nitrogen gas, acts as a coolant to the material (stops burning it) while using the maximum
power available, and allowing the laser to vaporize it.
Nitrogen protects the metal from corrosion:
• No oxidation of the steel occurs
• No additional heat is generated
• A high quality (clean-cut) edge is achieved
• The clean cut makes it easy to weld and paint or powder-coat the metal
• Paint will not fall off the edges
5. PAINTING PROCESS: CATAPHORESIS
The lifting beam is one of the most important components in our generators. This
structure is meant to stand 4 times the weight of the machine without plastic deformation.
For its painting, we apply a special process called, cataphoresis. It is based on electrical
deposition of anticorrosion material using anodes. It grants minimal risk against corrosion
compared with the traditional painting/coating processes.
This painting method is also applied in sensitive pieces of our Hilight range as the base
frame. Normally these pieces are not galvanized.
Main benefits are:
• Being equal thickness of the paint on all surfaces
• Being coat able of interior, exterior and corner part of the materials
• Decreasing environmental pollution to minimum through water-based system
• Maximum corrosion resistance
6. PAINTING PROCESS: POWDER
Our canopies are all finished and protected with a powder
coating paint. This polyester type of material, applied in
two layers, with a final thickness of 80-180 µm
(depending on the piece) gives an extreme resistance to
corrosion in aggressive environments.
MAIN PROCESS STEPS:
1. Pretreatment based in 4 stages:
Phosphatizing degrease,
wash, passivation and
blowing
2. Drying by forced convection heater
3. Natural cooling of the parts
4. Apply powder coating in cabin
TESTS:
The tests that the samples are involved:
1. Corrosion resistance: Salt spray test in accordance
with ISO 9227
Measurement of coating disbanding on either side
of the cross cut and from edges.
Measurement of blistering and corrosion degree
except edges and cross cut in percentage in
comparison with total exposed surface.
Sample: 83 µm galvanized and powder coated, after 870 hours in salted fog cabin
7. 2. Control polymerization rate on customer’s part by DSC analysis (Mechanical
properties)
Adhesion in accordance with ISO2409
Impact resistance (1kg 50cm) in accordance with ISO6272
PRIME PROCESS
Base frame is always the most punished system of a generator if we talk about portable
equipment. That’s why the design of our generator and light towers is robust enough to
support multidrop applications, but now also the paint is resistant enough to corrosion
and humid/tropical areas. In case of the containers range, the full structure is treated with
this process, achieving a thickness of 210 µm.
Typically and due to high costs, these metal sheets are not pre-treated, so instead of
using previous processes (Galva-Steel) we use a prime process with Epoxy resin (before
painting). Zinc phosphate epoxy primers are the most frequently encountered and give the
best durability within the group.
Priming ensures better adhesion of paint to the surface, increases paint durability, and
provides additional protection for the material being painted against environmental
agents.
Our primer process complies with standards as: ISO2409, ISO1520, ISO7253 (corrosion
and mechanical testings).
*Note: not all ranges have this process, please ask and confirm with Atlas Copco support.
8. CONCLUSION
What’s the impact of a rusty canopy?
Your brand image can be damaged, and your product can be perceived as a low quality
one. Even if the bodywork of the machine doesn’t affect to the performance, nobody
wants to buy/rent a deteriorated product!
Is that important for the performance?
Even if it doesn’t affect directly on the performance result, canopy is in charge also of the
protection of the main elements inside it. Higher maintenance costs could be a feasible
sales argument.
Why each piece of the structure suffers a different process?
In Atlas Copco we understand the needs of every “corner” of our machines, lifting beam
and base frame will not be challenged in the same in a construction site, so the design and
the treatments can not be neither the same. In addition, it is a way of being competitive in
terms of cost, supplying the best process to each piece.
COVER OUR CUSTOMERS NEEDS ARE IN
TERMS OF QUALITY, PERFORMANCE AND
LIFETIME, OUR MAIN GOAL TO ACHIEVE.
THAT’S WHY THE DESIGN OF OUR CANOPIES,
CONTAINERS AND BASE FRAMES ARE
TOGETHER WITH THE RAW MATERIALS USED
AND PAINTING PROCESSES, SO DETAILS
ANALAYSEZ AND TESTED.
9. All the described processes will not be efficient with a weak machine design, that’s why all our units have been improved with round
edges (mainly in canopies but also in QAS base frames) to facilitate the correct drying of the paint, avoiding irregularities of quantity
of paint, color of the paint… Below a summary table per engine range and process or treatment.
For any further doubt contact Atlas Copco technical support team.
STEEL TREATMENTS PAINT PROCESS
Galva Steel
canopy
Galva steel
critical parts*
Stainless Steel
Roof
N2 Cut base
frame
N2 Cut Canopy
Cataphoresis
base frame
Powder coating
canopy
Prime process lifting
beam
Prime process
base frame
Prime process full
container
QAS Kd S3A x x x x x x x
QAS Pd S3A x x x x x x x
QAS Vd S3A x x x x x x x
QAS Vd S2 x x x x x x x
QES Kd S3A x x x x x
QES Jd S3A x x x x x X**
QES Jd FCO x x x x X**
QES Vd S3A x x x x x
QES Vd S2 x x x x
QES Md FCO x x x x
QAC Cd x x x
QEC Cd x x
HILIGHT H5+ x x x x x x
HILIGHT B5+ x x x x x x
HILIGHT E3+ x x x x x x
*Critical parts: Mast, exhaust, base frame supports, hot parts… **Just in skid frame option
Atlas Copco does not assume responsibility for possible errors. Atlas Copco reserves the right to make changes without prior notice.