Galvanizing Engineering هندسة الجلفنة

  Galvanizing Flux : Wet or Dry Method  The advantages and disadvantages of the dry and wet methods are still disputed, which is better? But the choice depends to a large extent on the quality of the products for  galvanizing. The main advantages of the dry method • Higher production capacity. • Reducing the output Dross. • Lower operating cost. The main disadvantages of the dry method: • Needs a bath (more space) • Needs heating (energy consumption) • Needs continuous treatment or shut down to adjust the concentration of the tank and iron content  • These equipments need continuous and periodic maintenance.  The main advantages of the wet method: • Providing space and equipment (there is no bath or heating). • A layer of Flux on the surface of the zinc kettle gives a better cleaning of the products surface  especially when there were errors in the previous stages. • In general, it gives less thickness of zinc, especially if the product is pulled through th...

الفلكس  الطريقة الرطبة او الجافة    إن محاسن ومساوئ طريقتي الفلكس الجافة والرطبة مازالت موضع خلاف ، أيهما أفضل ؟ ولكن الخيار يعتمد إلى حد كبير على نوعية المنتجات المراد جلفنتها .   أهم محاسن الطريقة الجافة : ·        طاقة إنتاجية أعلى . ·        تقليل الدروس الناتج . ·        كلفة تشغيلية أقل . أهم مساوئ الطريقة الجافة : ·        تحتاج لحوض ( حيز كبير ) ·        تحتاج للتسخين (استهلاك طاقة ) ·        تحتاج لمعالجة مستمرة او توقف لضبط تركيز الحوض ومعالجة الحديد ·        تحتاج هذه التجهيزات لصيانة مستمرة ودورية .    أهم محاسن الطريقة الرطبة :   ·        توفير في المكان والمعدات ( لا يوجد حوض أو تسخين ). ·        طبقة الفلكس على سطح حوض الزنك تعطي تنظيف أفض...

Observations:  1-Reducing material consumption (zinc)  2- Reducing energy consumption   3- Increasing quality of production. Description : New research has developed a novel, METALLIC FLUX COMPUND, to reduce ash formation, theoretical, this compound will increase ash formation to 50%     Environmental feasibility:     1-    Reducing waste ash 2-    Reducing consumption of energy Economic feasibility: The total quantity of ash = 203.1 ton / y    in 2003   The zinc in ash = 203.1*0.7 = 142.17 The price of ash is considered as 55% zinc That mean = 0.41* 203.1 = 83.271 The loses = 142.17 – 83.271 = 58.9 ton saving / year The price of zinc per ton = 1253 Saving = 58.9 *1253 =73801.7 $  / year    Technical and organization consideration: The additives  depend on the amount of production 250 gr \ ton production 10976.632 *0.25 = 2744.158 kg The price of gold flux...

                                                                         1-        6 HCl + Fe 2 O 3 ----- 2 FeCl 3 + 3 H 2 O  2-             Fe + HCl  -------- Fe Cl 2 + H 2   The main concentration of pickling tank is 16% wt/ wt . The performance of the tank can't be effective when it reaches 5  wt/ wt . At this point the iron content is 150 gr / lit . it means you have  ore or iron mine . There is more than one option to treat this consumed acid : ·         Acid Regeneration : it can be used on or off line by using special type of resins in order to get rid of iron then concentrate  it to reach crystal stage as FeCl 3 and it is necessary to keep Fe ...

      A-       degreasant   1-    Degreasing: It is  used to remove organic substances or contamination   , the concentration of this material usually  10% wt/wt from tap water  2-    Actually 7.5% has been used in decreasing tank the, the process take place without problem in production 3-    The temperature of the tank is  75 c, there are neutral , alkaline and acidic degreaser .  4-    The dipping time is the same . 5 -    The method of check the concentration is necessary  to improve performance  and to  control .     B- pickling additive   1-     This additive is used as: a- inhibitor agent b- wetting gent c- anti – vaporization agent 2-     1.4% of the concentrated acid is added to the pickling tank from the pickling additive   3-     The use of t...

     There are two factors to be considered : 1 - The iron for galvanizing is a product and not galvanized for the purpose of maintenance. 2- If the option to choose the metal exists, it is desirable to choose iron  that gives us a high quality product within the basic criteria, including: 1- The chemical composition of the metal, especially the content of silicon, carbon and phosphorous .... etc . 2- The surface must be free of organic pollutants (dyes, paints, polymers, bitumen). 3-   No  high corrosion or  pores in the metal surfaces . 4- The thickness of the iron should be consistent and  no significant differences. 5- The design  of products should allow draining of molten zinc.