Zinc Dust: The Versatile Metal Granular Zinc In Industry Globally In Zinc Market In World
Zinc Dust: The Versatile Metal Granular Zinc In Industry Globally In Zinc Market In World
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Uses of Zinc Dust in Industries
Granular Zinc finds numerous industrial applications due to its properties. One of the major uses of Granular zinc is in zinc die casting where it is mixed with alloys to make zinc alloys. These alloys have a lower melting point than pure zinc and can be cast easily into molds. Products ranging from automobile parts to hardware are manufactured using zinc die casting. Around 50% of the total zinc produced worldwide is used for die casting applications.
Another important use of Zinc Dust is for manufacturing zinc-carbon batteries where Granular Zinc serves as the anode. Due to its high reactivity, zinc rapidly reacts during the electrochemical process involving oxidation and reduction reactions inside the battery. This helps in generating a steady flow of electrons, making zinc-carbon batteries suitable for many portable applications.
Being a reducing agent, Granular Zinc finds application in welding and metal finishing processes. In autogenous or self-feeding welding, a pile of Granular Zinc is ignited which reacts with oxygen to generate heat sufficient for welding metals like steel and aluminum. The molten zinc coating also protects the weld from corrosion. In metal finishing, Granular Zinc is used as a reducing agent for removing oxides and impurities from metal surfaces through chemical or thermal reduction methods.
As a pigment and corrosion preventive, Granular Zinc has versatile applications. Used as a pigment in industrial coatings and primers, Granular Zinc imparts corrosion resistance properties to the coatings. The volatile action of zinc protects surfaces by reacting with oxygen and water before they can reach the base metal. Zinc powder mixed with water-based paints is also commonly used for protecting steel structures from corrosion in coastal areas, chemical plants etc.
Manufacturing Process of Zinc Dust
Granular Zinc can be produced through various manufacturing routes with the common starting material being zinc sheets, pellets or ingots.
The most prevalent production method involves vaporizing zinc through heat treatment in distillation plants operating at temperatures around 907°C. As the zinc vapors cool down, they condense into very fine powder having particle size less than 150 microns. The Granular Zinc precipitates in collection chambers, from where it is extracted.
Another process involves atomizing molten zinc using high pressure water jets. As water comes in contact with the zinc stream, it rapidly solidifies into extremely fine powder. Particle size can be less than 10 microns using this atomization technique.
Mechanical production methods like ball milling are also employed on a smaller scale. Here, zinc fragments are ground down into a fine powder between grinding media inside rotating mills. However, thermal and atomization processes offer better yields, purity and particle size control for large scale production.
Regardless of the process, the Granular Zinc produced needs to undergo classification to obtain specific particle size fractions for different applications. Air classifiers or sieves are generally used to separate dust based on particle size. Finer grades below 75 microns find more uses in batteries, coatings etc.
Chemical Properties and Specifications
High purity Granular Zinc constitutes more than 95% zinc by mass. Main impurities may include iron, aluminum, and cadmium depending on the production method. Zinc has a melting point of 419°C and density of 7.13 g/cm3.
Some key chemical properties making Granular Zinc industrially useful include:
- High reactivity - Zinc readily forms zinc oxide or zinc carbonate on exposure to air or moisture. This property is exploited in welding, coatings etc.
- Ability to form alloys at low melting points - Alloys like pewter have melting points below 250°C enabling die casting.
- Reducing behavior - Zinc acts as a reducing agent due to its positive standard reduction potential.
Specifications for Granular Zinc vary as per applications and grades. Typical requirements could include a zinc content of 97-99%, particle size below 75 microns, moisture content below 0.5%, mesh size as per buyers need. Producers adhere to ASTM standards for different Granular Zinc types.
With properties like high reactivity, ability to form alloys, reducing behavior and corrosion resistance; Granular Zinc has emerged as an important industrial raw material. Its versatility is reflected in the wide range of applications from batteries to welding. Advances in zinc extraction and powder production technologies continue to expand usage of this valuable zinc form.
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