The minimization of unwanted dross build-up formation on the sink rolls in continuous hot-dip
galvanizing lines is a key goal of the industry. In this study, the CFD multi-physics modeling of
the surface reaction kinetics for dross build-up growth and the coupling to the mass transfer is
the basis for the evaluation of relevant process parameters. The results of a virtual Design of
Experiments were processed by neural network approaches, as well as linear regression
modeling to build a surrogate process model. It was found that the bath Al concentration has
the highest effect (> 80 pct) on the dross build-up rate on the sink rolls. Operating the zinc bath
at higher Al concentrations decreases the dross build-up reaction rate. Furthermore, it was
found by the CFD multi-physics model that the local dross build-up rate increases toward the
edges of the roll grooves which might lead to the occurrence of strip surface defects.