At a Glance

2008-CP-11-S2

Project Description

The aim of this project was to

research and implement an
environmentally efficient
continuous flux treatment system.
Potential treatment systems were
identified and the best available
technical, commercial and
environmental solution was
implemented.

Implementation of an Environmentally
Efficient Continuous Flux Treatment
System

The initial phase of the project focused

on identifying suitable technologies
which could be used for removing iron
from the galvanising flux. Commercial
vendors were researched, the
Galvanisers Association was contacted
for information and patents for flux
treatment technology were reviewed. A
shortlist of three potential vendors was
developed and each vendor attended
site to outline their proposal. Following
detailed discussions by the project
team, a flux treatment unit from HascoThermic was chosen.

The system chosen removes

dissolved iron from the flux
solution continuously, which
means that the site no longer
needs to dispose of the entire
contents of the flux baths.
Reducing the iron content has also
reduced the production of
unwanted by-products, which will
generate significant raw materials
savings. In addition to treatment
of the galvanising flux, the system
installed in the Dublin plant also
allows for the treatment and
reuse of spent stripping acid
which is rich in Zinc Chloride as
flux, further reducing the waste
which needs to be exported off
site.
Two treatment units were
installed, one in each of the Dublin
and Cork plants. The systems have
performed well to-date and the
initial results achieved have been
quite good. The reduction in
unwanted by-products in the flux
bath is expected to reduce zinc
consumption by approximately 63
tonnes. Costs associated with
exporting 130 tonnes of spent acid
will also be eliminated.
Annual net savings generated by
the onsite treatment of flux
amount to over 122,000 per
annum

Galco Steel Ltd., Ballymount Road,

Walkinstown, Dublin 1, Ireland.
Galco Steel Ltd. is the largest hot dip
galvanizer in Ireland with plants located
in Dublin, Cork, Waterford, Derry and
Tynagh (Galway). Galco Steel Ltd
employs approximately 340 between
the five sites, with the principle
operation in Dublin employing
approximately 175 people.. The Dublin
site has 2 galvanizing baths with the
remaining plants each having one bath.
Galco also produce a range of access
covers and drainage systems.
Aims of this project
In the galvanising process flux is used to
assist the alloying process. The use of
dilute hydrochloric acid for pickling (i.e.
surface cleaning) gives rise to a carry
over of iron from the acid into the flux.
In turn this iron leads to generation of
unwanted by-products in the flux bath.
Prior to this project, flux treatment
methods at Galco led to the generation
of significant amounts of hazardous
waste, which had to be treated off site
by a specialist treatment company at
considerable expense. This project
aimed to investigate potential methods
for the treatment of galvanising flux
onsite which would reduce the need for
disposal of used flux.

The system doses a fixed quantity of

hydrogen peroxide into a known
volume of flux. The peroxide reacts with
the dissolved iron to form iron oxide,
which precipitates out of solution.
Aqueous ammonia is dosed in to
maintain the pH. The solution is passed
through a filter press which retains the
solid iron oxide and allows the purified
flux to return to the galvanising plant.
Two units were installed in the Dublin
and Cork plants following considerable
preparatory works, such as modification
and retesting of bunds, installation of
underground pipes and containment,
mechanical and electrical connections.

The Flux Treatment Unit Installed in the

Dublin Plant.

Outcomes
By any measure the project has been
quite successful. The units installed
have reduced the dissolved iron levels
in the flux baths considerably. In turn
this has reduced the generation of
unwanted by-products namely Dross
(Fe/Zn alloy) and Ash (ZnO2). Ash
generation is down 25%, while
generation of Dross has decreased by
14%. A noticeable improvement in
the quality of products being
galvanised has also been achieved.

% Gross Zinc Consumption

Dross and Ash Concentration

0.9%
0.8%
0.7%
0.6%
0.5%
0.4%
0.3%
0.2%
0.1%
0.0%

Before
After

Dross

Ash
By-Product

Figure 1
By-Product Concentrations
The successful implementation of the
project has resulted in Environmental
Savings Achieved as outlined in Table
1 below.
Environmental Savings Per
Annum
Reduced Zinc
63 Tonnes
Usage
Spent HCl Disposal
130
Tonnes
The Economic Savings Achieved
outlined in table below
Economic Savings Per Annum
Reduced Zinc Usage
94,500
Spent HCl Disposal
32,250
Total Gross Savings
126,750
Additional Costs Per Annum
Chemical
2,840
Consumption
Power Consumption
1,680
Total Costs
4,520

In addition to the resource savings

outlined, a smaller volume of iron
oxide is collected in the filter press for
disposal. This filter cake is significantly
drier than the previous iron oxide
sludge which used to be collected
from the flux baths and sent for
disposal. Reducing the volume and
liquid content should make disposal
of the residual waste easier for waste
treatment companies.
Lessons
The general principle of this project is
transferable, i.e. to implement an
efficient, continuous regeneration
process which reduces the amount of
hazardous waste generated on site.
Most waste streams generated in
industry can be treated at source to
reduce the need for waste disposal.
The project also illustrates that the
process of identification and
characterisation of waste streams is
useful in identifying potential
opportunities to reuse materials
onsite rather than disposing of them.
This project may be extended to treat
flux from the smaller sites
(Waterford, Galway and Derry) in the
Galco group, subject to the necessary
approvals from the EPA. This would
allow the environmental and
economic benefits to be increased
without significant additional capital
expenditure.

More Information
For more information on this project
please contact:
Terry Hinds,
Galco Steel Ltd.,
Ballymount Road,
Walkinstown, Dublin 1,
Ireland.
email. dublin@galco.ie
Tel. 00 353 (0) 1 424 7000
Fax. 00 353 (0) 1 424 7001

The Cleaner Greener Production

Programme (CGPP) of the EPA is funded
under the National Development Plan 20072013. The CGPP was launched in 2001 as a
grant scheme to fund Irish organisations to
implement cleaner greener practices while
achieving significant cost savings.
Cleaner Greener Production is the
application of integrated preventive
environmental strategies to processes,
products and services to increase overall
efficiency and reduce risks to humans and
the environment.
Production processes: conserving
raw materials and energy, eliminating
toxic raw materials, and reducing
the quantity and toxicity of all
emissions and wastes
Products: reducing negative
impacts along the life cycle of a
product, from raw materials
extraction to its ultimate disposal.
Services: incorporating
environmental concerns into designing
and delivering services.
The programme aims are focussed on
avoiding and preventing adverse
environmental impact rather than treating
or cleaning up afterwards. This approach
brings better economic and
environmental efficiency.

This case study report is one of the reports

available from the companies that
participated in the fourth phase of the
Cleaner Greener Production Programme
(CGPP4), which is funded by the EPA STRIVE
and NWPP programmes. A summary of all
the projects containing all the reports are
also available.
More information on the programme is
available from the EPA:
Ms. Lisa Sheils,
Environmental Protection Agency,
Richview, Clonskeagh,
Dublin 14, Ireland

Total Net Savings

122,230

http://www.epa.ie/researchandeducation/research