Various types of machining processes done on steel components

leave residual oil and grease on the surface of the metal. Before efficient pre
treatment of the surface of the steel can be obtained suitable for galvanizing
this oil and grease has to be removed.
we used Hydronet Base as the chemical solution for
degreasing from soprin, Italy. Hydronet is a degreasing solution compatible
with pickling in hydrochloric acid (HCL). Hydronet has a special degreasing
action of deposit the sludge formed when oil and degreaser reacts on the
bottom of the tank while other de greasers are floating the sludge on the top
of the degreaser. This prevents pasting sludge on the surface of the item.
• It is compatible with pickling baths so it is not necessary
to rinse the artifacts before pickling.
• It performs a pre-pickling increasing the production
potential of the pickling itself.
• It reduces the pickling time by decreasing the attack of
hydrochloric acid on steel.
• Work at room temperature (best performance is obtained
by heating the solution from 30 ° C to 35 ° C.
• Best performance is obtained when PH value between 1.8-
2.0.
• This solution removes 20%-80% dirty from the surface.
• Degreaser consumption , 0.6-1.2 Kg/Ton.
• Cleaned the Tank
• Verified the volume of the tank.
• Calculated the required volume of Hydronet Base,
according to the ratio of 9:1 water and Hydronet.
• Firstly, Filled half of the tank with water, then added
calculated volume of hydronet to the tank, after water
added until fill the tank.
• Checked the PH value of the solution, it was 1.03
 We used early prepared samples of items to test the degreasing capability of the de greasing bath.
Samples with grease, lubrication oil and cutting oil were used because those kinds of impurities are affecting on
galvanizing process mostly. Also third party flat irons, Box bars and angles were used as samples.

Box bars

Grease Flat Irons

 We used box bars as the first testing item. Sporin agent advised to keep dirty items about 10 minutes
inside the degreasing bath. Items were checked after 10 minutes. But they are not cleaned properly because of the
high oil content. Then soprin agent advised to keep items another 10 minutes inside the bath. Checked again after 10
minutes and items were cleaned up to considerable level.

After 20 minutes.

Before
degreasing After 10 minutes.
 We used fabrication angles with grease, lubrication oil and cutting oil as test items. We select two items
from each type with impurities. One item was galvanized with normal process (pickling, rinsing, fluxing, drying and
galvanizing.) other item was galvanized with new process (degreasing, pickling, rinsing, fluxing, drying and
galvanizing). That methods helps to identify the effect of the degreasing on galvanizing process.
Raw materials with After galvanizing

Grease

Cutting oil

Lubrication oil
 With degrease Lubrication oil

Without degrease

With degrease
Cutting oil

Without degrease

With degrease
Grease

Without degrease
 Third party flat irons were galvanized with degreasing. Flat irons dipped 10 minutes twice. Oil content
was removed properly. But some glue material was remain.

Before degreasing After 20 minutes degreasing

In Process Monitoring report

After 10 minutes degreasing After galvanizing

Conclusion

• De greaser can remove cutting oil, synthetic oil and lubrication oil small quantities.
• It can’t remove Grease, oils which applied on steel for protecting purposes.
• Degreasing time is about 20 minutes.
 Immediately after the immersion of steel items in the hot galvanizing, molten zinc on the surface begin
to emerge of the ash that must be removed prior to the next extraction. These ash consists oxides and zinc chlorides
and metal zinc, the latter in the form of drops of various sizes that for the galvanizer represent a loss. the FLUX ZINC
is composed of salts and elements that facilitate the melting of the zinc metal contained in the ash, separating it
from the other components.
 Wrapped 300g of flux zinc in paper. Placed the package in a metal basket with long handle.
Basket was dipped in the bath area containing the drosses. Basket moves through all over the bath and removed ash
from the bath after extracting the basket from bath.

Preparing flux zinc package Purifying the zinc bath

 Flux made by mixing filmflux and fifty fifty. Calculated required quantity of filmflux, fiftyfifty
according to the capacity of the tank. Firstly added fifty-fifty and agitated the tank. Then film flux was added to the
tank. After preparing this solution, density must be higher than 1.18 Baume. but actual density value of the tank was
1.05 Baume.

Adding fifty-fifty Adding film flux Checking density