Solutions for galvanising plants

Continuous process control and extended service life of process baths.

In the hot-dip galvanising of carbon steel, a constant bath composition and a clean process stream are crucial to the quality of the zinc coating. Contamination by dissolved iron in the flux bath or iron-rich groundwater leads to increased zinc ash formation, loss of quality and a shorter service life for your baths.

PCA Water designs and builds robust installations for flux iron removal, process water treatment and sludge dewatering, specifically tailored to the demanding operating conditions of galvanising plants.

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Our applications & solutions

Flux iron removal

In the galvanising of carbon steel, it is important that the flux bath maintains a consistently low iron (Fe) concentration. A flux iron removal installation is the most suitable technique to achieve this.

In such an installation, the Fe is oxidised and then separated by dewatering to obtain a clear flux.

PCA can support you with this technology, in both the design and construction of the installation.

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Acid recovery

Acid recovery is an innovative membrane technology that converts contaminated pickling acid into a reusable pickling liquor and a metal-bearing concentrate. By recovering valuable free acid and selectively removing metal salts, you reduce your operating costs and maintain the quality of your pickling bath.

Optimise the efficiency and quality of your galvanising plant.

Would you like to drastically reduce zinc consumption in your galvanising plant, extend the life of your flux bath or safeguard your process water quality? Our experts calculate the feasibility and payback period of an iron removal installation for your site.

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Frequently asked questions about water treatment in galvanising plants

How much maintenance does an iron removal installation in a galvanising plant require?

PCA Water builds fully automatic skids using corrosion-resistant materials (such as high-grade plastics and specific alloys) that can withstand the acidic and aggressive environment of a galvanising plant. The control system manages the oxidation and rinse cycles autonomously, keeping manual intervention to a minimum.

How much flux solution is lost during the iron removal process?

Virtually none. By using a chamber filter press to dewater the oxidised iron sludge, the maximum amount of liquid is pressed out of the sludge cake and returned to the flux bath. Only the solid, dry iron hydroxide is disposed of.

Does the galvanising process have to be shut down to install a flux iron removal system?

No. Our flux iron removal installations are installed as a bypass (side-stream) system. The installation continuously draws off part of the flux solution, removes the iron and pumps the clean flux back to the bath. Your production process can continue without interruption.

Proven results in the metal and surface treatment industry

Discover how we help industrial partners in hot-dip galvanising and steel processing keep their baths clean, save raw materials and prevent quality deviations.

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