Ingots are the least expensive metallic forms of zinc, suitable for general and specialized applications. These materials are appropriate choices in case of loading and long transmission around the world. Zinc ingot manufacturers produce these multipurpose metals in assorted grades based on purity and density. Each of these qualities is employed in a particular industry as intermediate goods. Among the functions of zinc ingots are galvanizing processes, alloy production, die casting procedures, and the production of various zinc derivatives, such as zinc oxide.
If you are an in-demand company and seek the universal markets to find a perfect zinc ingot Supplier, here is a suggestion for you. Zinc Sulfate Co. is a prominent zinc ingot manufacturer and an international exporter of this metal. This company’s outcomes are produced under unique procedures to reach the most elevated results. In Zinc Sulfate Co.’s zinc ingot factory, the quality-approved raw material is utilized for processing the high-quality outcomes in standard grades like high grade (H.G.) zinc ingots with an average purity of 99.96% to 99.99%. You can employ our certified zinc ingots to make a final product reliably.
WHAT IS ZINC INGOT?
Zinc ingots, as intermediate goods, have various usage in many industries. To make a vivid understanding of zinc ingots’ properties and their usage, we should learn about the chemical element Zinc (Zn) in the first place, then tend to read about Europe and the Middle East zinc ingots.
Zinc is a metallic chemical element. It is classified as “Zn” on the periodic table, has an atomic weight of 65.37 and an atomic number of 30, and melts at 788°F (420°C). Although zinc is often a metallic gray tint, it can also be polished to a brilliant silver shine. At average temperature, zinc is a slightly brittle metal. It is the first element in the periodic table’s group 12 (IIB). Good to know that zinc and magnesium share a few chemical characteristics, including a single normal oxidation state (+2) and similar-sized Zn2+ and Mg2+ ions. Zinc consists of five stable isotopes, and this substance is the 24th most common element in the crust of the Earth. There are several kinds of zinc ore, with sphalerite being the most common. Australia, Asia, and the United States have the most significant working lodes. It is also worth mentioning that the zinc ores are refined using froth flotation, roasting, and electricity-powered final extraction to produce this vital element.
A zinc ingot is a block or bar of pure zinc metal cast into white or gray color and prepared for additional metal processing. Solid-state, crystallization, and ultra-high purification techniques, such as sublimation, are used to create the zinc ingot. Its characteristics include malleability, low maintenance, a long-lasting finish standard, purity, and great strength. The zinc ingots provide resistance to rust and have durable material strength. It is used in electrolytic galvanizing, photoengraving plates, zinc oxide, zinc plate, sacrificial anodes, and zinc balls, in addition to hot-dip galvanizing steel, which is a known usage of this material as an intermediate good.
DIFFERENT GRADES OF ZINC INGOT
As a vital metal in different industries, the zinc ingot contains various grades. Each of its qualities holds a large amount of zinc and meager portions of other chemical elements. For instance, high-grade zinc, one of the purest grades available, contains chemical elements below:
- 99.99% of Zn;
- ≤0.005% of Pb;
- ≤0.003% of Cd;
- ≤0.003% of Fe;
- ≤0.001% of Sn;
- ≤0.001% of Cu;
- ≤0.005% of Al.
There is a need to ensure that zinc meets the chemical composition requirements of lead, iron, cadmium, aluminum, copper, tin, and non-zinc metals. Furthermore, the material must be free of surface corrosion and foreign matter adhering to its surface. Zinc ingot manufacturers classify zinc metal distilled from ore or electrolyzed from other materials based on these factors into five grades: LME grade, special high grade, high grade, intermediate grade, and prime western grade. It is important to remember that zinc ingot prices are determined by the grade and purity of the zinc element.
There are also other methods of categorizing zinc ingot Factory products; In this way, zinc ingots will be classified into distinct categories for different uses. Below, you may discover some qualities of zinc ingot, specified to one of its primary uses, Continuous Hot-Dip Galvanizing.
THE GALVANIZING GRADE OF ZINC INGOT
Zinc is essential in continuous hot-dip galvanizing. Therefore, choosing the correct grade of zinc, such as constant galvanizing grade or master alloy, is necessary when creating a galvanized product that satisfies market demands. In this case, zinc ingot Suppliers should consider various conditions; For instance, close control of the amount of aluminum in the zinc is crucial to achieve adequate adhesion to the steel substrate. To do so, the galvanizer must be able to rely on a supply of raw zinc ingots with certain composition restrictions.
It is also worth mentioning that the goal above is conducted using several ASTM standards specified for zinc products. For example, the B852 Standard provides eight Continuous Galvanizing Grades (CGG) of zinc with aluminum levels ranging from 0.25 to 1.0 percent. As lead is generally an unwanted impurity in galvanize coatings, all but one of these grades restrict its content to 0.007%. While this specification allows for various compositions, it has considerably reduced the number of unique zinc grades previously used by galvanizing operations.
ZINC INGOT PRODUCTION PROCESS
Zinc ingot production involves a long story, from the mining stages to zinc purification and turning this chemical element into a marketable product called zinc ingots. So, we should know that it all starts with traces of zinc, which can be found almost wherever on the planet’s surface. Zinc is a naturally occurring element. Miners collect and transport zinc concentrate from mines across the world to various ports for the following processes. Train loads of zinc concentrate are then carried to the locations for a four-stage process that includes roasting, leaching and purification, electrolysis, and casting.
It is also worth mentioning that turning ore containing zinc into pure zinc is known as zinc smelting. Smelting zinc has historically been more difficult than smelting other metals, such as iron because zinc has a low boiling point. At the temperatures required for metal smelting, zinc is a gas that will escape from a furnace with the flue gas and be lost unless certain precautions are taken. Remember that zinc sulfide is the most common zinc concentrate processed, and it is obtained by concentrating sphalerite using the froth flotation method. Secondary (recycled) zinc material, such as zinc oxide, is also used in producing zinc sulfide. Around 30% of all zinc produced comes from recycled sources.
Please bear in mind that there are two universal techniques for smelting zinc concentrates and making a large variety of secondary or final products like zinc ingot: the pyrometallurgical and the electrolysis processes. Most zinc ingot exporters have a basket of this product made in both ways. It is first necessary to learn about another stage, roasting, before we can understand these significant smelting ways of zinc.
The roasting process:
Roasting is the high-temperature oxidation of zinc sulfide concentrates, producing impure zinc oxide known as “Zinc Calcine.” Raw materials – zinc concentrate and zinc oxides recycled from the steel industry – are fed into a fluid bed roaster at this step. This is the first step in the manufacturing process. Raw zinc minerals are burned with air in the roaster and converted into calcine. Calcine has the appearance of sand and a temperature of 950 degrees Celsius. It is also vital that the roasting process varies depending on the type of roaster utilized. Roasters are classified into three types: multiple-hearth, suspension, and fluidized-bed.
The roasting process is entirely automated and constantly monitored and controlled by a control center operator to achieve the most acceptable results. In this case, approximately 90% of the concentrate’s zinc is converted to zinc oxide. However, about 10% of the zinc interacts with the iron impurities in the zinc sulfide concentrates at roasting temperatures to generate zinc ferrite. Sulfur dioxide, a byproduct of roasting, is further processed into sulfuric acid, a commodity.
After the roasting stage, Asian or Europe zinc ingot manufacturers tend to choose one of the two processes: the pyrometallurgical and electrolysis processes. Each of these ways contains detailed steps for making a high-quality, pure outcome.
ELECTROLYSIS PROCESS
The electrolysis process is more commonly employed than the pyrometallurgical procedures. This technique is also known as the hydrometallurgical process, the Roast-Leach-Electro win (RLE), or the electrolytic process. There are four stages in this process: leaching, purification, electrolysis, and melting and casting.
Leaching:
During the leaching process, the generated calcine is dissolved in sulphuric acid. In practice, this is accomplished by a process known as double leaching. To extract the zinc from the zinc oxide, the calcine is first leached in a neutral or slightly acidic solution (of sulfuric acid) to remove the zinc from the zinc oxide. The leftover calcine is then filtered in concentrated sulfuric acid to extract the remaining zinc from the zinc oxide and ferrite. This technique produces a solid and a liquid outcome.
Purification:
The cementation technique is used in the purification process to purify the zinc further. It removes copper, cadmium, cobalt, and nickel from the electrolysis process using zinc dust and steam. Following purification, impurity concentrations are minimized to less than 0.05 milligram per liter. This process is often carried out in big agitated tanks. During the process, temperatures range from 40 to 85 °C, and pressures range from ambient to 240 kPa.
Electrolysis:
Electrowinning, a specialized form of electrolysis, is used to extract zinc from purified zinc sulfate solution. In a series of cells, an electric current is passed through the solution. As a result, zinc deposits on the cathodes (aluminum sheets), and oxygen forms on the anodes. In the procedure, sulfuric acid is also generated and reused in the leaching process. Each cell is shut down every 24 to 48 hours, the zinc-coated cathodes are removed and cleaned, and the zinc is mechanically peeled from the aluminum plates.
Melting and casting:
Depending on the end products, the zinc cathodes from the electro-winning factory may go through a different transformation stage in a foundry. Induction furnaces are used to melt zinc cathodes, which are then cast into commercial products such as ingots. Other metals and alloy components may be added to generate zinc-containing alloys for die-casting or general galvanization. Finally, using specifically built insulated containers, molten zinc can be transferred to adjacent conversion plants or third parties.
So, our intended outcome, zinc ingots, are produced after the melting and casting stage. Then, Zinc ingot exporters can move this product easily as an intermediate good to different factories for different purposes due to the shape of the product and the ease of loading and transmission.
PYROMETALLURGICAL PROCESS
there are also specific pyrometallurgical techniques that use carbon to decrease zinc oxide and then distill metallic zinc from the resulting mixture in a carbon monoxide-rich environment. A typical composition of 1.3 percent lead, 0.2 percent cadmium, 0.03 percent iron, and 98.5 percent zinc are the primary drawback of all pyrometallurgical processes, So the results are only 98 percent pure. Although this might be pure enough for galvanization, it is insufficient for die casting alloys, which need unique high-grade zinc (99.995 percent pure). In this case, Zinc must be refined to achieve this purity. In the end, it is helpful to know that in the Middle East zinc ingot manufacturers employ one of three ways below as a Commercial pyrometallurgical process:
- The electrothermic process;
- The blast furnace process;
- The Belgian-type horizontal retort process.
ZINC INGOT APPLICATIONS
Zinc, which has the chemical symbol Zn, is recognized for its bluish-silver color. The maximum melting point and boiling point of zinc metal, respectively, are 419.53 °C and 907 °C. Standard and jumbo ingots of zinc can be separated, as can the grades of the ingots, such as special high grade, continuous galvanizing grade, high grade, etc.
Around 13 million tons of zinc are produced worldwide each year. It is good to know that the pure, extremely malleable, high-strength zinc ingots are utilized in a variety of industrial fields, including furniture, rubber, automotive, chemical, making zinc alloy ingots, and rubber. The segmentation based on utility is as follows:
- Galvanizing steel to protect it from corrosion is a process that uses nearly 58 percent of the total amount;
- Approximately 14% of universal zinc is utilized for producing die casting alloys containing zinc as a vital element;
- Around 9% of zinc that is made yearly worldwide is employed in chemical and oxide production;
- About 10% of zinc is used in the castings business and Brass semi production.
In the following, we’re going into detail about zinc ingot usage in various industries and for multiple purposes.
THE GALVANIZATION PROCESSES
As mentioned before, the majority of zinc is utilized to galvanize other metals, like iron, to avoid rusting. Car bodies, lampposts, safety barriers, and suspension bridges are all made of galvanized steel. The steel items are submerged in pools of molten zinc ingots during the hot-dip galvanizing process so that the melted zinc ingots can be applied to all exposed steel surfaces. As a result, galvanized steel is given exceptional strength and is shielded against corrosion. Galvanizing iron and steel products are typically chosen for their affordability, ease of upkeep, durability, sustainability, and beauty.
It should also be noted that galvanizing can be done in several ways besides hot-dip galvanizing, such as:
- Electro-galvanizing;
- Sherardizing;
- Zinc Spray Galvanizing;
- Continuous Galvanizing.
ZINC OXIDE PRODUCTION
Zinc oxide ZnO is an inorganic zinc-based compound. It comes in the form of an insoluble white powder. Numerous materials and goods, such as cosmetics, dietary supplements, rubber, plastics, ceramics, glass, cement, lubricants, paints, ointments, adhesives, sealants, pigments, metals, batteries, ferrites, fire retardants, and first-aid tapes, contain ZnO as an ingredient. Good to know that there are direct and indirect ways of producing zinc oxide as a useful chemical compound, and zinc ingots are employed in these processes as intermediate goods.
THE ALLOY MANUFACTURING
Zinc is also respected as a vital participant in manufacturing several alloys like brass. To attain different mechanical, electrical, and chemical properties, copper (Cu) and zinc (Zn) can be mixed in different quantities to create the alloy known as brass. Due to its shiny, gold-like appearance, brass has been a preferred material for decorative purposes. Brass is utilized for doorknobs and drawer pulls. It has also been commonly used to create utensils because of its qualities, including low melting points, good workability (both with hand tools and with contemporary turning and milling machines), durability, and electrical and thermal conductivity.
The primary benefit of using zinc in many alloys, like brass, is that it naturally resists corrosion. The majority of metals, except for aluminum, are prone to corrosion. Zinc, however, can make a metal corrosion-resistant. This metal is also perfect for soldering applications since it has a low melting point.
ABOUT ZINC SULFATE CO.’S ZINC INGOTS
Zinc Sulfate Co. is a leading zinc ingot manufacturer that provides several grades of this product, each suitable for a specific industry. In Zinc Sulfate Co., we rely on our certified products, produced with high-quality raw material and evaluated to universal standards. Our zinc ingots are the outcomes of two equipped factories located in Poland and the other one in The Middle East. Inside each factory, experienced chemists are in service to balance each product’s chemical and physical properties and make a quality-approved outcome based on global specifications. Please remember that you always have the option to contact our office in Germany and ask for your intended grade of zinc ingot.
Furthermore, you have a range of logistics options when dealing with Zinc Sulfate Co. The packaging of zinc ingots complies with international requirements and is entirely safe for transport. Customers can choose the weight of each shipment when ordering their product in different ways of packing.
CONCLUSION
Zinc ingots are bars of pure zinc metal cast in white, silver, and gray colors for further processing and employment in various industries. The production of this intermediate good is a long way from ore mining to purification and smelting. All in all, there are two main ways of producing zinc: the pyrometallurgical process and the hydrometallurgical process; each contains various stages and complications. These procedures result in a large variety of zinc grades with multiple degrees of purity and different qualities. The zinc ingots contain several chemical and physical properties like resistance to rust and durable material strength. Since zinc ingots have such pure characteristics, they are associated with many industries, such as different ways of galvanizing, photoengraving plates, making zinc derivatives, and zinc plates.