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C.C.
Comm. 036 -1708 MM
29.08.2018
Communication to the Client
From: Eng. Morello Marco
To : John Basantes
CC : Andrea Balconi, Technical
Jobs: 2017-08

Subject: FIRST FILL PRODUCTS

Dear Mr Basantes,

please find below a list of materials to buy for the first fill-up of the hot-dip galvanizing plant.

1.0 Degreasing solution ( ACID TYPE )

Tank : D1
N° of tanks :1
Total content of 1 tank : 17,3 cu.m
Acid degreasing agent : degreasing solution phospho
hydrochloric-based acid containing
phosphates and surfactants
Bath temperature : 40-45°C
Degreasing solution % : 5-10% of the tank`s total volume
Storage for refilling : 1000-2000 lt
Estimated consumption : ~1.5Kg/Ton
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2.0 Pickling

Tank :D3-D4
N° of tanks :2
Total content of tank D3 : 17,3 m³
Total content of tank D4 : 27 m³
Total content : 44,3 m³
Pure product :hydrochloric acid in commercial
solution of 31-33%
Solution in the tank :50% of the tank`s volume
Bath temperature :20°C
Volume to buy for the 1st fill-up : ~25 m³
Storage volume for refilling : 3 m³ or 1 external tank for acid
Estimated consumption of 32% acid : ~25Kg/Ton
Corrosion inhibitor : 0,01-0,05% of the tank`s volume

Bath preparation:

fill in the tank for 50% with water and add the acid in its commercial solution till you reach the level.

3.0 Flux

Tank :D6
N° of tanks :1
Total content of 1 tank : 27 m³
Product :salt of ZnCl2 2NH4Cl
(weight = 56% ZnCl2, 44% NH4Cl).
Solution in the tank :585 Kg per m3 of the solution
Total quantity for the 1st fill-up : 15.795 kg
Bath temperature :45°C
Suggested storage for refilling : 1000Kg in sacks of 30/50Kg each
Salt estimated consumption : ~2,5Kg/Ton

Bath preparation:
fill in the tank for 50% with water and add the salts till you reach the indicated kg.
When adding the salts, it is necessary to agitate the bath with the addition of compressed air which
is blown with the help of rilsan tubes located in some points of the tank.

4.0 Pure Zinc 99.998%

Kettle :C
N° of kettles :1
Zinc theoretical content : 24 m³
Zinc real content -100mm : 23,04 m³
Weight : ~ 159 Ton
First fill-up : ~ 190 Ton
Ingot format: : ingots of 30Kg/each
Suggested storage for refilling : ~ 25Ton // 1 month of works
Zinc estimated consumption : ~70Kg/Ton

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The amount of the used zinc is divided in the following manner:

60-80% adhere to the material
40-20% produce ashes and Fe/Zn alloys which have to be removed periodically (7/10 days)
from the bottom of the kettle and which result in process waste.
This process waste can be sold at a price equal to 40-50% of the primary zinc cost.

5.0 Zn-Al alloy in ingots

Amount :0,005 - 0,01% of the kettle`s volume

6.0 Iron wires for the materials hanging

Diameter : 4 – 5 - 6mm
Quantity : 5000Kg for each diameter
Type : raw material – easily malleable

7.0 Chains in alloy steel for high temperatures

Diameter : 13 – 16
Length : 3-6 m each
Quantity : 10 pieces per diameter

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8.0 Ultrasound thickness gauge to control the zinc coating

Best regards,
Andrea Balconi

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