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Types of anodes manufactured
                      
Anode Characteristics
Offshore applications
                      
Manufacturing process
 
 

A celebrated name in Corrosion Protection Engineering, PSL designs, manufactures and installs sacrificial aluminum and zinc anodes for offshore applications.

 
 

Types of anodes manufactured

 
 
  • Bracelet Anodes

  • Segmented Bracelet Anodes

  • Tapered Anodes

  • Stand-off

  • Flush Type Anodes

 
     
 
         
 
 
 
 
 
 
         
 
     
 

The anode-manufacturing unit in Kandla is approved by Engineers India Ltd (EIL) and has type approval certificate. This state-of-the-art plant has mechanized foundry with induction furnace and spectrometer and has a manufacturing capacity of 6000 tons per year of sacrificial anodes for cathodic protection system.

It’s well equipped R&D and computerized Design & Engineering department carry out the study of cathodic protection design calculations, detailed engineering design and drafting for turnkey projects along with Boundary Element Method Analysis (BEM) for anodes distribution along the offshore platform.

 

 

Anode Characteristics

 
 

Chemical Composition

PSL-Al

PSL-Zn

In : 0.01 - 0.02%

Cd : 0.025 – 015%

Fe : 0.10% Max

Fe : 0.005% Max

Cu : 0.006% Max

Cu : 0.005% Max

Zn : 2.8 - 6.5%

Si : 0125% Max

Si : 0.08 - 0.2%

Pb : 0.006% Max

Al : Balance

Al : 0.1 - 0.5%

 

Zn : Balance

Electrochemical Efficiency (Amp.hr./Kg)

2500 - 2700

750 – 780

Anode Potential (w.r.t. Ag/Agcl Electrode)

-1.00 V to -1.1 V

-0.95 V to -1.03 V

Consumption Rate (Kg/A Yr)

3.2 - 3.5

11.2 - 11.7

 
     
 

Offshore applications:

 
 

• Refineries

• Petrochemicals

• Power Plants

• Fertilizers

• Metallurgical Industries

• Shipping

• Infrastructure Projects and others

 

 

Manufacturing process

 
 

Weighed quantity of aluminum ingots are charged in induction furnace and furnace is put on to raise temperature to about 750 ± 30 ° C. At this temperature, weighed quantity of silicon is added and heating is continued for another 10 - 15 minutes and then the required weighed quantity of zinc is added.

A weighed quantity of indium is added just before pouring the alloy melt into the preheated ladle.
Meanwhile, the moulds are inspected and cleant of dirt, etc.

The steel inserts are placed and checked for its positioning. Moulds are then heated to remove the moisture in the mould-wash and subsequently inserts are also heated for better bonding between aluminum and inserts.

The alloy melt is then poured into the mould, slowly and carefully, after removal of slag from the ladle. Temperature is recorded before and after each pour and precaution is taken that it does not fall below 7050C.

A total of six samples is taken in every heat i.e., two samples of cylindrical type for electrochemical test and one of circular type for chemical analysis at the start of the pouring and the same will be at the end of pouring. Both types of samples will be cast in separate moulds.

After pouring the melt, adequate cooling is done and the casting is removed after solidification. The hot casting is removed by crane, forklift or manually and kept in the inspection zone. After cooling down of the casting, anode is inspected visually for its surface condition and is punched with heat number, anode number, size and date of manufacturing.

Visually rejected anodes are sent back for re-melting and accepted anodes are sent to the workshop for cutting and finishing of risers, runners etc.

The finished anodes are then weighed and checked for its dimensional tolerance and are then kept in the final inspection zone.

 

 

 
 
 

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