Dross Formation in the

Galvanizing Kettle

By Bernardo Duran
 Goal of Presentation

Discuss why dross forms in the 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

Troubleshooting Guideline: Reducing Dross

Pimples

AGA Resource Library

Your pickling and flux solution suppliers