Panel Discussion: Thermoplastic Tanks & Maintenance

Come hear different perspectives from several industry experts (Crighton Plastics, APR Plastic Fabricating, and galvanizing plant supervisors) on materials, maintenance/repair, and replacement of polypropylene tanks and more. This panel will be Q&A format with some guidance questions to aid the discussion. Bring your questions!

Small Group Discussions: Pretreatment Maintenance & Chemicals Safety

Attendees will break into small groups led by TechForum planning committee members to discuss and exchange ideas on tank heating materials, vapor control, iron maintenance, safety of chemicals, and lessons learned. This is a great opportunity to meet and learn from other operations personnel in the industry.

In-Person Plant Tour Preview: Valmont Coatings - West Point Galvanizing & Valley Galvanizing

Come learn about what to expect on Wednesday’s galvanizing plant tour of Valmont Coatings - Valley and Valmont Coatings - West Point. At Valley we will see galvanizing operations, small pole manufacturing (including trap shear and big wheel welder), and large pole manufacturing (including base weld, seam weld, and large press break). Lunch will be held at the Valley Cafeteria. At West Point we will see galvanizing operations.

Bob Woods

Zaclon, LLC

Why Pretreatment?

Many industries are seeing the loss of experienced personnel---the “brain drain”, including the after-fabrication hot-dip galvanizing industry. As a consequence, some of the tools and tricks of the industry have to be re-invented; but even more, the purpose and reason behind the pretreatment process becomes overlooked or undervalued. Without the "big picture" in mind, this adds confusion or hazards for newer employees, and can impact the productivity and profitability of the galvanizing plant. This presentation will set the tone of the conference and review: the pretreatment steps in the galvanizing process, the purpose and capabilities of the various chemicals in the galvanizing plant, what to look for, and lessons learned. Introduction will be given by Chair of the AGA Technical Services Committee.

Many industries are seeing the loss of experienced personnel---the “brain drain”, including the after-fabrication hot-dip galvanizing industry. As a consequence, some of the tools and tricks of the industry have to be re-invented; but even more, the purpose and reason behind the pretreatment process becomes overlooked or undervalued. Without the "big picture" in mind, this adds confusion or hazards for newer employees, and can impact the productivity and profitability of the galvanizing plant. This presentation will set the tone of the conference and review: the pretreatment steps in the galvanizing process, the purpose and capabilities of the various chemicals in the galvanizing plant, what to look for, and lessons learned. Introduction will be given by Chair of the AGA Technical Services Committee.

Liuba Shaplyko

Sirio Impianti Industriali

Turbines for Accelerating Pickling Times vs. Static Baths

Turbines are able to produce vigorous and effective pickling solution recirculation which can help homogenize the bath solutions and accelerate the reaction of the reagents on the immersed steel surface. This presentation will review a real-world case study at a galvanizing facility where turbine technology was shown to reduce pickling times. This technology also provides opportunities to use lower acid concentrations or extended maintenance cycles. Sizing and maintenance of turbines will also be discussed.

Kevin Halstead

Valmont Coatings

Experience using the Kleingarn Curve

The Kleingarn curve describes the effect of iron concentration on pickling rates at 20 C (68 F) for hydrochloric acid. This information allows galvanizers to regenerate solutions by removing a part of the ineffective solution and replacing it with fresh acid, water, or the contents from another bath to lower the iron concentration and improve cleaning times. This practice greatly extends the life of the bath, reduces purchased acid, minimizes disposal, and overall improves sustainability of the HDG process.

Despite these benefits, less than half of facilities with hydrochloric acid use this practice. This presentation will review some practical aspects of using the curve along with some lessons learned from a chemical engineering perspective.

Bryan Cullivan

Beta Control Systems, Inc.

HCl Recovery System Technology & Maintenance of Sulfuric Acid Recovery Systems

This presentation will review hydrochloric acid recovery system technology (vacuum evaporation) as well as practical maintenance topics & remote monitoring for sulfuric acid recovery units (crystallization process). Case studies and lessons learned over 40 years will be reviewed.

Chris Schermerhorn

Sabre Industries

Virtual Plant Tour of Sabre Industries (Sioux City, IA)

Sabre is a leading manufacturer of steel communication and electric transmission infrastructure products in the United States. The 100,000 sq-ft expansion project including the galvanizing plant and supporting offices completes the new business campus in the city's Southbridge Business Park.

Maulik Patel

Radadia Engineering INDIA

The Encapsulation of Pre-Treatment Areas for Various Plant Scales: Insights and Economic Considerations

Large-scale plants with capacities up to 1000 MT Zinc, as well as entry-level plant sizes can benefit from enclosed pre-treatment tunnels. These encapsulations provide substantial environmental benefits, durability due to the lack of internal metal fastening exposure, a controlled scrubbing system, safety, and cost-efficiency for the main factory shed, as well as several operational advantages, including electricity savings and reinforcement of the shed over the project's lifespan

This presentation will cover experiences with enclosed pre-treatment tunnels or scrubbers, lessons learned with minute detailing, economy, and operational ease.

Andrew Bennison

TIB Chemicals AG

Analyzing Your Pre-treatment

Only through a consistent, effective, and efficient pretreatment is economical and high-quality hot-dip galvanizing possible. This presentation will review the analysis of pretreatment baths, an overview of different techniques available, and recommendations for testing frequency. Some analysis methods are readily and economically performed at the plant, while others require complex and expensive equipment from a laboratory. Learn the pros/cons of each and the purpose behind them.

John Roy

Connecticut Galvanizing

PFAS & TRI Reporting

This presentation includes guidance for galvanizers & suppliers navigating changes to Toxic Release Inventory (TRI) Reporting of per- and polyfluoroalkyl substances (PFAS) and supplier notifications. Galvanizers and suppliers should act immediately and begin accounting for PFAS containing materials in preparation for the 2024 reporting year. It is anticipated the task of identifying these materials will be time-consuming and an earlier accounting will increase the opportunities available to reduce or eliminate sources of PFAS.

On October 20, 2023, USEPA issued a Finalized Rule to Require Enhanced TRI Reporting of PFAS (see summary from USEPA) eliminating the de minimis exemption for reporting of per- and polyfluoroalkyl (PFAS) substances. The de minimis exemption had allowed facilities to disregard the amounts of PFAS in chemical mixtures at concentrations below 1% (0.1 % for carcinogens). With this final rule, companies can no longer use the de minimis exemption for PFAS reporting and must account for even small concentrations of PFAS.

Paolo Carniato

Soprin

Toward Zero Liquid Discharge Pretreatment: A Quick Look

Liquid disposal is increasing its costs day by day and the bureaucracy for managing it is becoming always more complicated. How can the galvanizer react to this evolving situation? This presentation will cover hydrochloric acid recovery unit technology as well as other ways to manage the pretreatment line.

Angela Curtis

Hasco-Thermic

A Potential Digital Solution to Automate Quality Management System in the Pretreatment Process

Achieving a high-quality coating begins with meticulous surface preparation. Ensuring the metal is free of grease, dirt, and scale is critical before the galvanizing process. Accurate surface preparation is vital for the reliability and durability of the steel-zinc alloy, particularly in hot-dip galvanizing. Pioneers in the field have started implementing quality management systems such as Six Sigma and ISO 9001 to enhance control over pretreatment parameters. In recent years, the galvanizing industry has embarked on a digital transformation, introducing technologies that offer significant opportunities to reduce costs, increase efficiency, and enhance sustainability. This paper explores a potential digital solution to automate the existing quality management system in the pretreatment process of galvanizing plants, aiming to achieve more effective product quality management through precise control over key parameters in the pretreatment process line.

TBC

TBC

Tank Heating & Coil Materials

A properly specified heat transfer system can improve your process while saving energy. However, any materials need to withstand corrosive attack from caustic, pickling, and flux solutions. This presentation will review the different variables that go into sizing and materials for the heating coil you will need including pros/cons and lessons learned. Maintenance of heating coils will also be reviewed.