Plant design of inorganic zinc silicate paint

1. A PROJECT BY
SANDEEP BHAGAT -06
GAJANAN HANGE - 22
PAWAN JAMADAR – 23
PROJECT
GUIDE
Prof.
A.R.GANGWAL

2.  Literature Survey.
 Process Flow Diagram.
 Material and Energy Balance.
 Piping and Instrumentation Diagram.
 Detail Equipment Design.
 Plant Layout.
 Costing and Economics.
 Safety and Environmental Studies.

3.  The zinc silicate primer has to it’s the name
the promise of perfection for the long run.
 It is useful in highly corrosive areas like
chemical factories and refineries etc.
 Zinc is a self sacrificial metal its gives full
protection to the metal.

4.  Anticorrosive primer for protection of steel .
 Resistant to dry heat up to 4500 C .
 Solid content by volume % = 69% .
 Recommended dry film thickness= 75microns
 Estimated spreading rate=9.2 sq m/l
 Gives cathodic protection to the metal
 The paint is very sensible to application condition .
 Drying time for top coating is about 24hrs.
 Zinc rich coatings are abrasion resistant and rock
hard.

5.  Synthesis of Zinc Silicate Using Silica from
Rice Hull Ash (RHA) Through Solid-State
Reaction

6.  Successful synthesis of Zn2Sio4 powders using solid state
reaction of the ZnO powder precipitate and amorphous
cristobalite SiO4 powders from processed rice hull ash at
800≤T≤1000oC is presented
 Methodology
 Zinc silicate(Zn2Sio4 ) is synthesized using equimolar
concentrations of zinc sulfate (ZnSO4) and sodium hydroxide
(NaOH) producing zinc hydroxide (Zn(OH)2).
 The addition of strong electrolyte (ZnSO4) and strong base
(NaOH) in an aqueous solution results to the exchange of
ions. The formation Zn(OH)2 and Na 2SO4 is the product of ion
exchange.
 ZnSO4(aq) +2 NaOH(aq) Zn(OH)2(s) +Na2SO4(l)

7.  The resulting solution is filtered and washed with
distilled water. The precipitate is mixed with
appropriate amount of silicon dioxide (SiO2) in water
with constant stirring at an elevated temperature of 80
0C .
 However, the water is used as an amalgamation medium
to promote the adhesion of Zn(OH)2 particles on the
surface of SiO2 creating a nucleation site where Zn(OH)2
particles coat SiO2. The reaction mechanism for this
process is
 Zn(OH)2(s) + SiO2(s) Zn(OH)2(s) + SiO2(s) +
H2O(g)

8.  The precipitate is washed with distilled water and
dried at 100 0 C. The dried precipitate is annealed
at 800, 900 and 1000 0C .
 Solid-solid diffusion is expected to occur at these
temperatures. The mixing stage promote the
adhesion of smaller particle Zn(OH)2 to the surface
of SiO2 allowing the formation of Zn2SiO4 at lower
temperature
 2 Zn(OH)2 (s) + SiO2(s) Zn2SiO4 + H2O(g)

9.  Segments: 1) ships 2) offshore 3) Industry
 Objects : New constructions / Maintenance
Exterior and interior, above and below water

10. Very good corrosion protection
Very good solvent resistance
Very high heath resistance
(max 400oC)
Very high mechanical strength
Very good adhesion to blast cleaned steel
Relatively good recoat ability

11.  Alkyl enamels can not be applied directly over
IOZ.
 Higher application skill required.
 Takes long time to dry.
 Recoat time is more.
 Greater than recommended film thickness
causes mud cracking,

12.  Process Flow Diagram.
 Material and Energy Balance.
 Piping and Instrumentation Diagram.
 Detail Equipment Design.
 Plant Layout.
 Costing and Economics.
 Safety and Environmental Studies.