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