Leading Manufacturer of Slender stand-off anodes and also aluminium anodes, sacrificial aluminum anode, aluminium hull anodes, aluminium anodes for ballast tanks and aluminum tank anodes, Aluminum anode, Zinc anode, Magnesium anode, MMO anode, MMO anode with titanium from Mumbai.
About Slender stand-off anodes.
In these types of anodes, the anode material is not in direct contact with the surface to be protected, and there is a gap (hence the name stand-off). The insert is generally a tubular one which can be welded or bolted to the surface.)
The benefit of a stand-off design is that it is a more compact design, and the anode material is better utilized in a stand-off design. This is quantified by a parameter called ‘anode utilization factor’. This is the fraction of the anode material which is actually utilized over the lifetime of the anode. For flush anodes, this is around 80%, while for stand-off anodes it is 85 to 90%. Thus, stand-off anodes are better utilized over their lifetime.
Further, in case of flush anodes, due to constant contact between the anode material and the surface, the surface may suffer from embrittlement caused by deposition of ions from the anode material to the cathode (the protected surface).
That said, stand-off anodes protrude from the surface on which they are installed. When used on external hull of a vessel, these affect the streamlined shape of the vessel, and lead to increased drag and higher powering requirements. In comparison, flush anodes are closer and more compliant to the vessel’s geometric shape and have lower effect on resistance. Thus, flush anodes are usually preferred on outer hull due to their low drag properties.
Both Flush mounted and slender stand-off anodes are further classified into Short and Long, depending on their ratio of length to width. The length affects the resistivity of the anode and thus its current capacity.
Uses of Slender stand-off anodes
Aluminum slender anodes mostly can be applied in sea water & sea mud environment, whereas Zinc slender stand off anodes can be applied in sea water, mud water and brackish (river) water environment.
Aluminium anodes have several advantages, they are much lighter in weight, and have a much higher capacity than Zinc.
The followings are some steel structures can be protected by slender anodes are as follows:
• Offshore structures: any kind of platforms, subsea/submarines pipelines, FPO, FPSO, MODU, SPAR, subsea structure, risers, mud mad, dog legs, wind turbine, etc.
• Inshore structures: ports, harbors, jetties, wind farms, sea water intake, locks, dams, bridges, piers, reclamation’s pile / sheet pile, etc.
There are three basic methods of securing the anode to the surface which is to be protected. They are
- Welding
- Bolting
- Using studs/brackets
Aluminum slender anodes mostly can be applied in sea water & sea mud environment, whereas Zinc slender stand off anodes can be applied in sea water, mud water and brackish (river) water environment.
Aluminium anodes have several advantages, they are much lighter in weight, and have a much higher capacity than Zinc.
The followings are some steel structures can be protected by slender anodes are as follows:
• Offshore structures: any kind of platforms, subsea/submarines pipelines, FPO, FPSO, MODU, SPAR, subsea structure, risers, mud mad, dog legs, wind turbine, etc.
• Inshore structures: ports, harbors, jetties, wind farms, sea water intake, locks, dams, bridges, piers, reclamation’s pile / sheet pile, etc.
There are three basic methods of securing the anode to the surface which is to be protected. They are
- Welding
- Bolting
- Using studs/brackets
Manufacturing Process of Anodes.
Anodes are large carbon blocks which are used to conduct electricity during the aluminium reduction process. The heat generated by the reduction process is used to bake the pitch into the carbon form required for reaction with alumina, thus recycling the waste energy in the pot.
Weighed quantity of aluminum ingots are charged in induction furnace and furnace is placed on to boost temperature to about 750 ± 30 ° C. At this temperature, weighed quantity of silicon is added and heating is sustained for an additional 10 – quarter-hour then the specified 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 get rid of the moisture within the mould-wash and subsequently inserts also are heated for better bonding between aluminum and inserts. The alloy melt is then poured into the mould, slowly and punctiliously, after removal of slag from the ladle. Temperature is recorded before and after each pour and precaution is taken that it doesn’t 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 among circular type for qualitative analysis at the beginning of the pouring and therefore the same are going to be at the top of pouring. Both sorts of samples are going to be cast in separate moulds. After pouring the melt, adequate cooling is completed and therefore the casting is removed after solidification.
The recent casting is removed by crane, forklift or manually and kept within 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 producing . 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 within the final inspection zone.
Application of Anodes
• Refineries
• Petrochemicals
• Power Plants
• Fertilizers
• Metallurgical Industries
• Shipping
• Infrastructure Projects and others
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