Metallic Zinc Powder

Metallic Zinc Powder

Areas of Use, Benefits, Sectors

Learn about the uses of metallic zinc powder in galvanizing, sherardizing, batteries, metallurgy, chemistry, pyrotechnics, and hydrometallurgy; as well as the safety and standards involved.

What is Metallic Zinc Powder?

Metallic zinc powder (Zn) consists of fine zinc particles produced in a gray color and varying grain sizes. It is produced in high purity and, due to its fine structure, has very high reactivity. Because of these properties, it is a very important raw material in corrosion protection, battery production, chemistry, hydrometallurgy, and special chemical synthesis.

Main Areas of Application

1) Corrosion Protection – Zinc Powder Paints

• Zinc powder is the main pigment in primer paints called zinc-rich primers. These paints, conforming to ASTM D520 and ISO 3549 standards, provide cathodic protection to steel, preventing rust.

2) Sherardizing (Dry Galvanizing)

• Small or complex metal parts are heated in sealed drums filled with zinc powder at 300–500 °C. Zinc vapor diffuses into the steel, forming a protective layer of Zn–Fe alloy. This method is defined by the ISO 17668 standard.

3) Thermal Spraying

• Zinc wire or powder is sprayed onto the surface to obtain a protective coating. It is particularly used in the corrosion protection of large metal structures. Process details are specified in the ISO 2063 standard.

4) Batteries

• Zinc powder acts as the anode in alkaline batteries. It is also a key component for high energy density in zinc-air and silver oxide-zinc batteries. In modern battery designs, the particle size and additives of zinc powder are critical for performance and safety.

5) Hydrometallurgy and Cementation

• In solutions containing gold and silver, zinc powder is used to precipitate the metals (Merrill–Crowe process). It also acts as a cementing agent in removing some ions, such as copper, from solutions.

6) Organic Chemistry

Zinc powder is used as a reducing agent and reactant in organic synthesis. For example:

• Reformatsky reaction: Forms organozinc compounds from α-halo esters.

• Simmons–Smith reaction: Used to convert alkenes into cyclopropane rings.

7) Pyrotechnics (Limited and Historical Use)

• In the past, zinc powder and its derivatives were used in military smoke munitions. However, this use has been largely abandoned today because the ZnCl₂ aerosols produced by combustion are toxic.