Metguard Application in Hazira Steel Plant: Tackling Corrosion in Cold Rolling Mill

Location: Hazira, Gujarat (Coastal Industrial Town)

Industry: Steel Manufacturing (Cold Rolled Sheet Metal Production)

The steel plant in Hazira, situated in the coastal industrial hub surrounded by large industries, specializes in the production of sheet metal, with a key focus on Cold Rolling of Hot Rolled Sheets. The cold rolling mill operates in a highly aggressive environment, primarily due to the use of hydrochloric acid during the pickling process. This acid has the capacity to rapidly dissolve metal, posing a severe corrosion risk to the plant's infrastructure.

Corrosion Challenges in Steel Manufacturing

The steel manufacturing process, from the reduction of iron ore to iron, releases a range of corrosive pollutants, including sulfur dioxide (SO2), nitrogen oxides (NOx), ammonia, and hydrogen sulfide (H2S). These pollutants, when combined with moisture, form acidic compounds that contribute to widespread corrosion. Sulfidic corrosion caused by sulfur products is particularly destructive, inducing severe internal stresses in steel structures, which can lead to structural failure.

In addition to these pollutants, downstream processes such as Cold Rolling utilize hydrochloric acid, which undergoes acid regeneration to restore its strength, creating an even more corrosive atmosphere. Further processes, including fluxing and galvanizing, emit acid vapors that attack nearby steel structures. Additionally, multiple tank pre-treatment steps before coil coating generate corrosive liquid discharges, including chromate-based aqueous streams known to be carcinogenic.

Metguard's Proven Corrosion Protection in Hazira

In the face of such hostile conditions, Metguard has proven to be an effective corrosion protection system, particularly in environments like the cold rolling mill. Here’s how Metguard addresses corrosion in this aggressive setting:

• Protection Against Acidic Corrosion: Metguard’s advanced passivation technology shields metal surfaces from the harsh effects of hydrochloric acid and other corrosive pollutants present in the mill.
• Sulfidic Corrosion Resistance: Metguard prevents the destructive effects of sulfidic corrosion caused by sulfur emissions, protecting critical infrastructure from internal stresses and material degradation.
• Long-Term Durability & Minimal Maintenance: The application of Metguard ensures long-lasting protection, reducing the need for frequent maintenance and lowering overall lifecycle costs.
• Environmentally Friendly Solution: Free from harmful substances such as lead, chromates, and isocyanates, Metguard offers a safer and more sustainable corrosion protection solution in such industrial environments.

Conclusion

The application of Metguard in the steel plant’s cold rolling mill has demonstrated its effectiveness in tackling the severe corrosion challenges posed by hydrochloric acid, sulfur products, and other pollutants. By providing robust, long-term protection, Metguard has significantly enhanced the durability of plant infrastructure, minimized maintenance needs, and contributed to safer operations in this highly corrosive environment.

Metguard Application in Kandla Fertilizer Unit: Addressing Corrosion in Fertilizer Manufacturing

Location: Kandla, Gujarat (Near Rann of Kutch and Kandla Port)

Industry: Fertilizer Manufacturing (Chemical Fertilizers)

The fertilizer manufacturing unit in Kandla faces extreme corrosion challenges due to its coastal location near the Rann of Kutch and Kandla Port. Along with environmental factors, the handling of highly corrosive chemicals in fertilizer production significantly increases the threat to the plant’s infrastructure. The unit, with an annual production capacity of 9,16,600 MTPA (P2O5), produces a variety of complex fertilizers, including DAP, NPK, Zinc Sulphate Monohydrate, and water-soluble fertilizers like Urea Phosphate, 19:19:19, and 18:18:18.

Corrosion Challenges in Fertilizer Manufacturing

The production and handling of fertilizers involve storage and piping systems exposed to highly corrosive chemicals such as sulfuric acid, phosphoric acid, hydrofluoric acid (HF), hydrochloric acid (HCl), and fluorosilicic acid. These acids, combined with vaporous emissions, create an aggressive environment that leads to rapid degradation of metal structures. The coastal humidity further exacerbates the issue, accelerating the corrosion process.

Key areas affected by corrosion in the unit include:

• Chemical Storage Tanks: Continuously exposed to corrosive acids like sulfuric and phosphoric acids.
• Piping Systems: Handling hazardous chemicals that lead to severe corrosion, posing risks to plant safety and efficiency.
• Vapor Emission Zones: Emit corrosive fumes that affect surrounding structures and equipment, intensifying the risk of material degradation.

Metguard's Corrosion Protection in Kandla

In such a corrosive environment, Metguard was applied to safeguard critical infrastructure from the damaging effects of both environmental and chemical corrosion. Here’s how Metguard provided a solution in Kandla:

• No Metal Loss & Increased Durability: Metguard’s advanced passivation technology protects metal surfaces from acidic chemical exposure, preventing metal loss and significantly extending the lifespan of storage tanks, pipes, and other critical structures.
• Resistance to Acidic Corrosion: Metguard is specially formulated to withstand corrosive chemicals like phosphoric, sulfuric, and hydrochloric acids, commonly encountered in fertilizer production.
• Environmentally Friendly: Metguard is free from hazardous substances such as lead, chromates, and isocyanates, making it a safer and more sustainable solution for industrial applications.
• Easy Maintenance & Reduced Costs: Metguard requires minimal maintenance post-application, ensuring long-term protection and reduced lifecycle costs in high-risk areas.

Conclusion

The application of Metguard in the Kandla fertilizer unit has effectively tackled the severe corrosion challenges posed by corrosive chemicals and the coastal environment. Metguard’s ability to provide long-lasting protection has enhanced the durability of key infrastructure, reduced maintenance needs, and ensured a safer, more efficient production environment.