galvanizing kettle and methods to decrease its formation. Overview Definition of dross
Why dross formation matters
How dross forms
How to reduce dross formation and
its negative effects on the finished product Definition of Dross
Byproduct of the galvanizing process
which consists of loose iron particles (iron salts) that have metallurgically reacted with zinc in the galvanizing kettle.
Dross can contain more than 94%
zinc (6% iron). Why Dross Formation Matters Aesthetic concerns from dross pimples. Steel can be rejected for gross dross inclusions. Dross formation accounts for approximately 15% of the zinc usage in the galvanizing process. Dross formation can be reduced. How Dross Forms
Free iron particles in the galvanizing
kettle metallurgically react with zinc to create dross particles rather than the zinc reacting with the steel to create a galvanized coating. Types of Dross Floating Dross: free particles of dross that can float throughout the kettle and usually consist of long intermetallic spikes interwoven in clumps; hollow-like structures
Bottom Dross: dross particles that
aggregate (settle) to the bottom of the galvanizing kettle Floating Dross Dross Pimples Dross Pimples Gross Dross Inclusion Where the Free Iron Particles Come From Iron salts formed by a reaction between pickling agents and steel
Iron salts formed by reaction
between flux and steel
Zinc/iron alloys formed by a direct
reaction between steel and molten zinc (loose iron particles on the steel) Iron Salts from Pickling Agents Pickling agents react with iron oxide and the steel to create iron salts.
Creates loose iron salts that can
then be transferred to subsequent tanks if not rinsed properly. Iron Salts from Reactions with Flux
Fluxing agents such as ammonium
chloride and zinc chloride can form iron salts when reacting with the steel which can then be carried over to the galvanizing kettle. Free Iron from Zinc/Steel Reaction Loose particles of iron from the iron or steel that comes off while in the kettle can go on to create dross particles.
Reactive steels can develop excess
zeta layer formation which can flake off crystals that create free iron particles. New Galvanizing Kettles Dross formation can be high in new kettles until a layer of intermetallic layers form on the kettle walls, which then usually inhibits further dross formation. Reducing Dross Formation Limiting formation of iron salts during pickling operation Adequately rinsing iron salts after pickling operation Monitoring iron levels in pickling and flux baths, and galvanizing kettle Elemental additions to galvanizing kettle Avoiding large temperature swings in galvanizing kettle Limiting Iron Salt Formation During Pickling Inhibitors can be used which limit the attack of the acid on the steel while not affecting dissolving action of the iron oxide and mill scale on the steel
Monitor pickling time to ensure
steel is not over pickled Adequate Rinsing of Pickling Salts Allow enough time for pickling salts to drain before transferring the steel to the rinse tank
Allow enough time in rinse tank
Implement a second rinse tank
when possible/practical Monitoring Iron Levels in Pickling and Flux Solutions Frequently check iron levels and pH in pickling tank and rinse tanks
Frequently check iron levels in flux
(should be no greater than 0.5%)
Aim for an iron level of about 0.1%
in the galvanizing kettle (iron solubility will vary with kettle temperature) Properly Maintain Flux Solutions Dross formation can be higher in wet flux method than dry method
Agitation of the flux in the dry
process can help to convert excess iron to sludge
Work with flux supplier to find
optimal chemical levels and filtering strategies Elemental Additions to the Galvanizing Kettle Small additions of lead (1%) can reduce dross formation, but the industry is moving away from lead use in kettles Nickel additions (0.04 to 0.09%) can reduce floating dross (however, nickel decreases the solubility of iron and can increase bottom dross formation); (see iron solubility on next slide) Adding elements to kettle in smaller quantities more frequently is preferred over bigger quantities less frequently Iron Solubility in Zinc and Zn-Ni (Courtesy of Teck) Maintaining Consistent Temperatures in the Galvanizing Kettle Iron solubility increases with increases in kettle temperature (see graph on next slide)
When temperature drops, the iron
precipitates out of solution which is then available to form dross
Uppermost level of zinc can be cooler than
lower levels of zinc and have lower iron solubility Solubility of Iron in Zinc with Varying Temperatures Removing Dross from Kettle Bottom dross should be removed on a scheduled basis, whether by time or steel volume throughput
Nitrogen can be bubbled in zinc
(ensure bottom dross is not disturbed) to float dross to the surface where it can then be scooped out Conclusion Reducing dross formation: Increases profits because less zinc is consumed in the form of dross
Makes for happier customers since
there are less dross inclusions on the steel Additional Resources Galvanizing Note: Skimmings & Dross