THE MANAGEMENT OF

CONTINUOUS
GALVANISING BATH

IT’S A SHINY BLUISH-WHITE METAL

ATOMIC WEIGHT : 65.39

ATOMIC NUMBER : 30
MELTING POINT : 419.58 0 C
BOILING POINT : 907 0 C
SYMBOL : ZN
PROTECT THE BASE METAL (STEEL)
FROM CORROSION.
SACRIFICE ITS LIFE TO KEEP THE
BASE METAL ( STEEL ) HEALTHY.

IT’S A SILVER COLORED METAL

ATOMIC WEIGHT : 26.9815
ATOMIC NUMBER : 13
MELTING POINT : 660.2 0 C
BOILING POINT : 2500 0 C
SYMBOL : AL
MOST IMPORTANT ELEMENT IN BATH.
ACT AS AN INHIBITOR BETWEEN ZINC
AND BASE METAL ( STEEL ).
DROSS MODIFIER.
ADHERENCE
ETC……
IT’S A BLUISH-GREY CHEMICAL ELEMENT

ATOMIC WEIGHT : 207.19

ATOMIC NUMBER : 82
MELTING POINT : 327.5 0 C
BOILING POINT : 1740 0 C
SYMBOL : Pb

SPANGLE FORMATION.

LEAD IS A FRIEND OR FOE. ??????

IT’S A BLUISH-WHITE CHEMICAL ELEMENT

ATOMIC WEIGHT : 121.75

ATOMIC NUMBER : 51
MELTING POINT : 630.74 0 C
BOILING POINT : 1586.85 0 C
SYMBOL : Sb

SPANGLE FORMATION.
SHINY APPEARANCE.

IT’S A WHITE METAL

ATOMIC WEIGHT : 118.71

ATOMIC NUMBER : 50
MELTING POINT : 231.9 0 C
BOILING POINT : 2270 0 C
SYMBOL : SN

SHINY APPEARANCE.

IT’S A SILVER-WHITE METAL

ATOMIC WEIGHT : 55.85

ATOMIC NUMBER : 26
MELTING POINT : 1535 0 C
BOILING POINT : 3000 0 C
SYMBOL : SN

INCOMING SOURCE : STEEL STRIP

IT’S A FOE FOR GALVANISING BATH.

DROSS GENERATOR.
ETC……
Heat Inputs : 1. Burners.
2. Heat from Strip…….. (1)

Heat out puts : 1. Heat required for Ingot melting.

2. Heat losses.
3. Heat taken out by the Strip….(2)

Tburners + T strip = T ingots + T losses ……………….. (1)

If Tstrip > T bath ………………………………………………… (1)

Tburners = T ingots + T losses + T strip ……………….. (2)

If Tstrip < T bath………………………………………… (2)

CASE 1 : If Tstrip > Tbath

If the strip temperature is greater than the bath
temperature, Iron dissolution from strip, until
1. Strip temperature = Bath temperature.
2. An inhibition layer form.
CASE 2 : If Tstrip < Tbath
If the strip temperature is lower than the bath
temperature, Iron dissolution from bath, until
Strip temperature = Bath temperature.
An inhibition layer form.
In both the cases the reaction depends upon the
strip thickness.
Case 3 : If Tstrip = Tbath
In this case the Fe dissolution is controlled as the
Temperature balance between Strip & Bath.

1. Maintain the Bath Temperature constant.

2. Maintain the Dipping temperature in such a way
so that your bath temperature does not increase
or decrease.

If Bath temperature Increase It means

your Tstrip > Tbath

If Bath temperature Decrease It means

Your T strip < T bath

If Bath temperature Maintain the Set-Point

Your Tstrip = T bath
Aluminum (Al) – 0.16 to 0.20% for GI; 0.11 to 0.14% for GA
Lead (Pb) – Nil to 0.10%
Antimony (Sb) – Nil to 0.10%
Iron (Fe) – 0.015 to 0.03%
Zinc (Zn) – Balance. High purity
Bath Temperature : 455 0 C to 480 0 C

High diffusion rate between the zinc and steel

Alloy layer grows fast and uncontrolled, as in batch galvanizing

This binary alloy is hard and very brittle and cannot withstand much bending without
delaminating from the steel

The secret of continuous hot-dip galvanizing is slowing the diffusion reaction in a

controlled manner.

Act as an Inhibitor between Zinc & Steel Reaction.

Modify solubility of FE . ( AL FE solubility )
Dross Controller.
Adherence
Weld ability
Paint ability
Corrosion resistance
Viscosity ( AL Viscosity )

Aluminum is required in the zinc bath to inhibit the zinc-iron reaction.

Effective aluminum is the amount of aluminum dissolved into the molten zinc. It does not
include the aluminum present in the dross particles, Coating.

1. Material
Zinc ingot chemistry
Aluminum bar chemistry
Steel strip – chemistry, thickness, width, roughness

2. Method
Coating weight
Steel strip – speed, temperature
Bath temperature, pot heating method
Sampling method
3. Machine
Pot –condition, heating elements, hardware condition
Sampling tool
Sampling mold
4. Man
Additions – zinc ingot, aluminum bar, antimony bar
Dross removal
Sampling practice and location
5. Measurement System
(accuracy, precision, resolution, calibration)
Optical emission ICP (bath chemistry)
Pot thermocouple (bath temperature)
Gauges – strip thickness, coating weight,
strip temperature, line speed,
strip length, strip width.

1. GET THE ALUMINIUM/ IRON PERCENTAGE IN BATH

FROM LAB SCREEN ( C1FGS084 ).
2. CONSIDER BATH LEVEL AS 100.
3. CONSIDER AVERAGE ZINC WEIGHT AS 28 KG.
4. CALCULATE THE SURFACE AREA USING THE
5. FORMULA SA = SPEED * WIDTH * TIME.
6. AT THE BEGINNING OF THE SHIFT WE GOT THE
7. SURFACE AREA TO BE PRODUCED IN THAT SHIFT.
8. ACCORDING TO SURFACE AREA CHARGING
9. RECOMMENDATION DONE.
STEP 1 : PUT THE ACTUAL BATH LEVEL
IN BATH LEVEL FIELD.
STEP 2 : PUT THE ACTUAL AVERAGE WEIGHT OF
ZINC INGOT IN THE AVG WT FIELD.
STEP 3 : PRESS THE REFRESH BUTTON.
STEP 4 : FOLLOW THE CHARGING
RECOMMENDATION, IT WILL TAKE
YOUR BATH TO LEVEL = 100 &
AL = 0.17.
• THE OPENING AL TAKEN FOR CALCULATION IS THE RESULT OF YOUR
PREVIOUS SHIFT

STEP 5 : ADJUST THE CHARGING AFTER GETTING

THE LAB RESULT IN YOUR SHIFT..
STEP 6 : AT THE END OF THE SHIFT INSERT THE
NO OF ZINC CHARGE , NO OF AL CHARGE
& THE TOTAL WEIGHT OF DROSS ( KG ).
IN THE ACTUAL CHARGING FIELD.

STEP 7 : PRESS THE SAVE BUTTON.

STEP 8 : PRESS THE DATA BUTTON.
STEP 9 : SELECT DATE & SHIFT.
STEP 10 : EXECUTE.
STEP 11 : NOTE DOWN THE DATA

1. THIS MODEL WILL NOT CALCULATE

IF THE LINE IS STOP.

ACTION : START THE LINE,

WAIT FOR A COIL TO CUT AT EXIT.

2. IF THERE IS ANY PROCESSED COIL IN

“UP” CONDITION, THE SYSTEM WILL
NOT CALCULATE.

ACTION : MAKE THE COIL “PR”