TY - THES

T1 - Development of an analytical reduced zinc bath model for predicting temporal temperature, aluminum, and iron concentrations during the continuous galvanizing process

AU - Zaismann, Lena

N1 - embargoed until 18-10-2029

PY - 2024

Y1 - 2024

N2 - In the hot-dip galvanization process, the formation of dross particles in the zinc bath and dross build-up on zinc bath hardware, negatively impacts the quality of the produced coating. CFD simulations of the zinc bath provide insights into which process conditions favour the formation of these particles. However, using simulations to control the industrial galvanizing process in real time is uncommon, as their computation is extremely time-consuming. A reduced analytical model is therefore developed in Python that uses current process data to predict future dross formation rates in the galvanizing process and supports the user in improving product quality. This model utilizes energy balances to calculate the zinc bath’s mean temperatures. Mass balances are used to generate aluminum and iron concentrations and combined with thermodynamic relationships and kinetics to predict the global dross formation rates. The model is validated by comparison with process data provided by voestalpine.

AB - In the hot-dip galvanization process, the formation of dross particles in the zinc bath and dross build-up on zinc bath hardware, negatively impacts the quality of the produced coating. CFD simulations of the zinc bath provide insights into which process conditions favour the formation of these particles. However, using simulations to control the industrial galvanizing process in real time is uncommon, as their computation is extremely time-consuming. A reduced analytical model is therefore developed in Python that uses current process data to predict future dross formation rates in the galvanizing process and supports the user in improving product quality. This model utilizes energy balances to calculate the zinc bath’s mean temperatures. Mass balances are used to generate aluminum and iron concentrations and combined with thermodynamic relationships and kinetics to predict the global dross formation rates. The model is validated by comparison with process data provided by voestalpine.

KW - Feuerverzinkung

KW - Zinkbad

KW - Model

KW - Rate der Schlackepartikelbildung

KW - hot-dip galvanizing

KW - zinc bath

KW - model

KW - dross formation rates

U2 - 10.34901/mul.pub.2025.040

DO - 10.34901/mul.pub.2025.040

M3 - Master's Thesis

ER -