Flux Treatment Systems

Efficient Flux Treatment Systems for Hot-Dip Galvanizing Plants

Proper flux treatment is a cornerstone of any high-performance industrial galvanizing line. The ANI Metal Flux Treatment System is designed to recover, purify, and recycle your spent galvanizing flux, ensuring consistent steel preparation, reducing chemical consumption, and minimizing environmental impact.

Why Flux Treatment Matters

In a typical zinc coating process, parts emerge from the acid-pickling stage and are dipped in a molten ammonium chloride flux to remove oxides and improve zinc adhesion. Over time, spent flux becomes contaminated with iron salts and dissolved metals, leading to:

• Inconsistent coating quality due to poor flux activity

• Higher chemical costs as fresh flux must be added more frequently

• Elevated wastewater treatment needs to meet environmental compliance

An optimized Flux Treatment System addresses these challenges by reclaiming usable flux, maintaining precise formulation, and cutting both waste and operating expenses.

Key Features of ANI Metal Flux Treatment Systems

Multi-Stage Clarification
Suspended iron hydroxides and solid particulates are removed via a combination of settling tanks and high-efficiency filter presses—yielding up to 95 % pure flux for reuse.

Automated pH & Concentration Control
PLC-driven dosing pumps maintain flux concentration and pH within ± 0.05 units, ensuring every part receives a uniform, active coating layer.

Compact Modular Design
Skid-mounted units can be installed alongside new lines or retrofitted into existing galvanizing plant operations, minimizing installation downtime.

Integrated Heat Exchanger Option
Preheats make-up flux to bath temperature, reducing thermal shock and preventing zinc splatter on cold parts.

Real-Time Monitoring & Reporting
Built-in sensors track flux purity, iron content, and temperature—generating automated alerts when maintenance is required.

Operational Benefits

• Lower Chemical Consumption: By recycling up to 80 % of your flux, you dramatically reduce ongoing galvanizing flux purchases.

• Enhanced Coating Consistency: Fresh-quality flux ensures optimal wetting and adhesion, producing a uniform, defect-free zinc layer.

• Reduced Wastewater Load: Cleaner rinse streams mean less burden on effluent treatment systems and fewer discharge fees.

• Improved Plant Safety: Enclosed treatment modules and automated controls limit operator exposure to acidic mists and hot flux.

• Energy Savings: Optional preheat recovers waste heat from exhaust gases—cutting fuel use in flux make-up by up to 15 %.

Maintenance & Best Practices

• Weekly Filter Press Checks: Inspect cake thickness and cycle frequency to maintain optimal clarifier performance.

• Monthly Bath Analysis: Sample recycled flux for iron content; adjust coagulation dosing to keep solids below 0.1 %.

• Quarterly Valve & Pump Service: Verify dosing-pump accuracy and replace worn diaphragms to prevent under- or over-dosing.

• Annual PLC Calibration: Confirm sensor accuracy for flow, temperature, and pH measurements to ensure reliable automated control.

Return on Investment

Most customers realize full ROI within 9–12 months through:

• Up to 50 % reduction in fresh flux procurement

• Lower effluent-treatment costs

• Fewer downtime incidents from clogged nozzles or inconsistent flux baths

Elevate your metal protection solutions with the ANI Metal Flux Treatment System—maximizing flux efficiency, improving coating quality, and ensuring a cleaner, safer plant. Contact us today for a custom proposal and start reclaiming your flux!

Flux Treatment Systems – Hot Dip Galvanizing | ANI METAL

Flux Treatment Systems – Hot Dip Galvanizing | ANI METAL