Beni Suef Steel — Galvanizing Flux Optimization for Coating Uniformity
Switching to CHIMI FLUX improved zinc coating uniformity by 35% and reduced zinc dross by 20% at a structural steel galvanizing plant.
Challenge
A hot-dip galvanizing facility processing structural steel and transmission tower components was experiencing inconsistent zinc coating thickness, with bare spots and excessive dross formation. The existing flux bath was poorly maintained, with iron contamination above 8 g/L and unstable Baumé density, leading to a 15% rejection rate on coating thickness inspections.
Solution
CHIMI ART performed a complete flux system overhaul: the old flux was drained and the tank chemically cleaned, then refilled with CHIMI FLUX Powder dissolved to the optimal 14°Bé concentration. ART CLEAN 15 degreaser was introduced as a pre-treatment step. A maintenance protocol was established with daily Baumé and pH checks, weekly iron level monitoring, and monthly complete analysis.
Results
- 35% improvement in coating thickness uniformity (CV reduced from 28% to 18%)
- 20% reduction in zinc dross formation, saving approximately 6 tonnes of zinc per year
- Rejection rate dropped from 15% to below 3%, with zero bare-spot complaints