CORDIS provides links to public deliverables and publications of HORIZON projects.
Links to deliverables and publications from FP7 projects, as well as links to some specific result types such as dataset and software, are dynamically retrieved from OpenAIRE .
Deliverables
Original research objectives:
The industrial problem to overcame in General Galvanising is relevant to an overall cost reduction of the process/product and quality improvement. Due to the great variety of steel parts coated by a hot-dip galvanizing plant a very interesting innovation is the set-up of a methodology for the production of good quality galvanized parts at competitive cost and with special attention to the environment.
Based on some preliminary results obtained with a modified aqueous flux solution, the goals of this project were:
- 20% reduction of the interface reactivity of so-called reactive steels in a molten zinc bath in order to achieve for these steels the same quality of non-reactive steels;
- 0.5-1% reduction of the Zn/steel ratio in the galvanising shop;
- 25% reduction of fumes emission in the galvanising shop;
- 25% reduction of top dross.
Projects actual outcome in terms of technical achievements:
The study is directed toward the set-up of a new flux formula and to a better knowledge of the influence of the parameters for a process in which the new flux solution will be used.
It has been found in the 1st year of research that in batch hot-dip galvanizing the traditional flux solution containing Zn and Ammonium chlorides may be substituted by a new not-traditional pre-treatment of the steels, based on the chemical deposition of a thin Cu-layer by means of the cementation reaction. This new low-cost Cu-route allows the addition of Al in the range of 0.025-0.05 wt% to the molten Zn-bath and therefore the complete inhibition of the Fe-Zn reaction for the so-called reactive steels. Furthermore because of the metallic nature of the pre-treatment the complete elimination of fumes emission during galvanizing, has been achieved.
The process has been scaled-up at a pilot scale and promising results were confirmed by experiments run in the pilot plants placed in the galvanising shop of 3 partners.
- With the new coating process the coating thickness for steels, whose Si content is placed in the reactivity pick, is more than 30% inferior while is it is unchanged for not-reactive steels. This is very important because a generalised reduction extended to non-reactive steels might affect the minimum coating thickness prescribed by Norms.
- The coating reduction has a positive effect on the reduction of Zn consumption per ton of galvanised steel. Nevertheless it depends on the steel-mix processed in the galvanizing shop. A most accurate value must be calculated on a long lasting campaigns run at a demonstration plant scale.
- Fumes emission during hot-dip galvanising is nearly nil with the new flux formula.
- The reduction of top dross formation has been noted during pilot trials. Also in this case the accurate value will be calculated on a long lasting production campaign.
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