Recent projects
Galvanizer (Turkey)
A general Galvanizer in Turkey who also coats own product, wanted to optimise the process in order to improve quality, and reduce costs.
Over the time of a three days visit, the first day was spent analysing the existing operation, and deciding priorities for improvement. We see the improvements with the highest payback as the priority – making money is essential in all businesses, so the biggest return gets the most effort for improvement.
All areas of the operation were surveyed, and highest priorities for improvement turned out to be energy consumption, zinc consumption and volume throughput. Its often the case though that close inspection of all machinery reveals improved operations in other areas too. In this case the white fume filter was found to be almost totally ineffective. This was found to be due to poor understanding of how it works and poor maintenance practices. Immediate improvement was possible, with a plan for future practical improvements also passed on.
An energy reduction plan was devised with low cost remedies for several areas of unnecessarily high consumption. This will result in a reduction of 100kWh/tonne processed.
Zinc consumption reduction plans to achieve a reduction in gross zinc consumption by 0.5% (to 4%)
Infra Red survey of the furnace waste gas ducting showed heat losses that are able to be eliminated
The white fume filter was found to have severe air leaks reducing its performance to almost zero
General Galvanizer (New Zealand)
This company operates a small plant servicing various industries in its area. An initial 2 day visit resulted in many recommendations for improvement.
The burners on the furnace were found to be a poor choice, and were subsequently changed. Burners more suited to a water heating boiler were in use. These burn relatively inefficiently for galvanizing use, with a yellow flame indicating low flame temperatures. The new burners show much more efficient blue flame with resulting savings in fuel.
The pretreatment chemistry was found to be in poor shape and some simple measurement techniques for monitoring were introduced and people trained in their use.
A return visit a year later was requested, and huge improvements were noted. This second visit led to a new set of priorities for a second round of improvements. Within the somewhat restrictive space of the building, a new tank layout possibility was identified and the company intends making these changes introducing a rinse tank where there was none previously. This will further reduce zinc consumption.
Old burners with a yellow flame
New burners improved energy efficiency
General Galvanizer (Africa)
During a week-long visit, this company was found to have extraordinarily high zinc consumption. This was a clear priority, and that consumption was quickly halved, and is still reducing now. A second visit was requested after 2 years to assess the improvements and suggest more.
Plant location was rationalised, closing one of the 2 kettles in use and concentrating all production into a single kettle.
Pretreatment chemistry had been a mystery previously, but employees were trained in chemistry techniques to analyse their own chemicals, and consumption has improved, but more importantly zinc consumption is reduced. The company is now working on a plan provided to modernise the furnace temperature control. In two steps to allow spread investment, this will gain far longer kettle life than was previously being experienced.
Decommissioning one kettle to concentrate all production in one single kettle
In-house chemistry checks were allowed by setting up a small laboratory and training production people to do the analysis