Unparalleled Combinations
For almost all galvanizers the principal cost problems are
Those can cost you your bottom line if not managed
At Gongda Galvanizing we have the tools to assist you to manage those critical problems
The tools are:
· Laboratory procedures to give you accurate results using simple and reliable wet chemistry techniques
· Software to assist you to interpret the meaning of those results
· Q’s & A’s to take you through diagnosis of problems
· Internet assistance to solve problems
· Access to advanced analytical tools such as metals analysis
· Training tutorials on a subject by subject basis in ordinary everyday language
These tools compliment our range of equipment which include:
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Prep line management procedures and software to optimize your process to reduce all costs
◆ Advanced Immersion Heated, Ceramic Kettle to reduce dross and energy consumption
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Flash pre-flux or pre-flux iron reduction to reduce dross and increase fluidity as a means of achieving accurate coatings
◆ Counter flow rinse systems to eliminate the need to discharge waste rinse water and to recover process chemicals
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Computer controlled cranes to aid in controlling and optimising the preparation and galvanizing process
◆ Efficient nickel addition to economically give even surfaced, compact, bright coatings even when working with reactive steels. Alloy viscosity is reduced to give thinner coatings
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Post galvanizing chemicals to protect the fresh zinc surface against oxidation
The practical results are:
◆ Accurate coating – best practice is to within 3 microns
◆ Minimal dross production – zero to 25% of normal
◆ Greatly reduced ash make – 25% to 80% of normal
◆ Improved surface appearance particularly when using nickel
◆ Greater assurance of product quality
◆ More production
◆ Reduced liquid and gas discharges
◆ Little solid waste to discharge
The financial results are dramatic:
◆ 8% to 30% reduction in zinc consumption
◆ Reduced energy consumption – up to 30%
◆ Increased revenue from reduced downtime for dross removal – up to 5% additional production
◆ Increased revenue from enhanced quality – one jobbing galvanizer increased production by 150% as a consequence of much improved surface appearance
◆ Increased revenue and reduced costs from reduced reworking
Prep line management procedures and software
A rigorous set of control procedures are applied to ensure:
◆ Each stage of the process is carried out under the same conditions each day. The process is moved from an art form to one of scientific control
◆ Complex analysis of changing conditions is handled by easy to use software to ensure that the operators know how much of what has to be added when
◆ Process control information is captured and presented for interpretation
Ceramic kettle
A thermally efficient, one piece ceramic kettle with a 20 year life ensures accurate control of the galvanizing temperature while ensuring no iron enters the molten zinc from the material of the kettle. Energy sources are electricity, gas or oil
“Flash” pre-flux
This Gongda developed and patented procedure applies a zinc-rich seal to the work before the hot dipping process precisely preparing the work for the hot dipping process and thus ensuring that:
◆ Little iron enters the molten zinc from the work:
◆ Reducing dross
◆ Maintaining good fluidity of the melt & good run-off
◆ Reducing misses
◆ improving adhesion
◆ Improving malleability of the coating
◆ Improving surface appearance
◆ 25% of normal ash production
Pre-flux ferrous iron reduction
Where it is not practical to apply the “flash” pre-flux process Gongda has developed a semi-automated ferrous iron removal process and management plan which maintains the concentration of ferrous iron in the pre-flux below 0.6 g/l and generally about 0.1 g/l to:
◆ Reduce dross make
◆ Ensure excellent fluidity of the melt & good run-off
Efficient nickel addition
Past methods of nickel addition saw either most of the nickel end up as dross or a complex addition process which was not practical in most galvanizing shops. The Gongda process calls for the simple hand addition of a formulated tablet of nickel to the surface of the galvanizing bath.
The nickel tablet is formulated to ensure that 99%+ of the nickel is dissolved into the alloy without the formation of dross.