• Corrosion Science and Technology
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• 제9권4호
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• pp.159-163
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• 2010

Precise coating weight control is very important issue on quality and minimizing operating costs on continuous galvanizing line. These days, many steel making companies are having a new understanding of cost importance by rise raw material prices and customer's requirement for cost reduction. Dongbu steel also meets these situations and decided to develop the technologies. Dongbu Steel developed Integrated coating weight control system jointly with Objective Control Ltd. and installed 2CGL and 4CGL. Several technological functions were developed and realized to achieve true hands-off operation and maximum cost benefit by combining model-based preset and dynamic prediction models. We also installed it on 1 CGL on April, 2008. This paper will present the interface, functions and application result of the integrated coating weight control system including Zn saving and coating weight uniformity.

• 제어로봇시스템학회:학술대회논문집
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• 제어로봇시스템학회 2001년도 ICCAS
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• pp.121.5-121
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• 2001

For the last decade, remarkable progress in the coating weight uniformity of hot dip galvanized product has been made to overcome the tightening quality constraints and produce cost-effective galvanized products. This progress results from research and development works for more efficient air knife, more accurate model of coating process, more precise measurement of coating weight and more efficient control logics. The activities for an efficient mathematical model to predict coating weight and several control logics which has been implemented on the No.1 CGL, No. 2 CGL, and PGL at KwangYang Steel Works are reviewed in this article.

• Corrosion Science and Technology
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• 제9권3호
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• pp.105-108
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• 2010

The product specification of the Continuous Hot Dip Galvanizing Line (CGL) changes and varies constantly with different customers' requirements, especially in the zinc coating weight which is from 30 to 150 g/$m^2$ on each side. Since the coating weight of zinc changes often, it is very important to reduce time spent in the transfer of target values changed for low production cost and yield loss. The No.2 CGL in China Steel Corporation (CSC) has improved the control of the air knife which is designed by Siemens VAI. CSC proposed an experiment design which is an $L_9(3^4)$ orthogonal array to find the relations between zinc coating weight and the process parameters, such as the line speed, air pressure, gap of air knife and air knife position. A non-linear regression formula was derived from the experimental results and applied in the mathematical model. A new air knife feedforward control system, which is coupled with the regression formula, the air knife control system and the process computer, is implemented into the line. The practical plant operation results have been presented to show the transfer time is obviously shortened while zinc coating weight target changing and the product rejected ratio caused by zinc coating weight out of specification is significantly reduced from 0.5% to 0.15 %.

• 제어로봇시스템학회:학술대회논문집
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• 제어로봇시스템학회 1995년도 Proceedings of the Korea Automation Control Conference, 10th (KACC); Seoul, Korea; 23-25 Oct. 1995
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• pp.323-327
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• 1995

A new air knife system for coating thickness control in hot dip galvanizing process had been developed and installed on the CGL in Pohang Steel Works, POSCO. This new system consists of air knives with remotely adjustable nozzle slot and an automatic control system which can control both longitudinal and traverse coating deviations. Based on the optimal control algorithm, a traverse coating deviation control was designed. The controller controls the lip profile of the air knives with flexible structure according to the deviation of coating weight. From the measured values which are dependent on the strip width, the lip gaps are calculated with optimal algorithm and the model of the coating deviation. Time delay between knives and a coating thickness gauge is solved by the Smith Predictor.

• 한국표면공학회지
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• 제34권2호
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• pp.115-124
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• 2001

Gas wiping process of continuously hot-dip galvanized coating on steel strip has noise and coating problems. To improve the qualify of product, characteristics of air flow on the steel surface must be investigated. In this paper, fluid dynamic model of the gas flow is setup and solved numerically using STAR-CD. The effects of edge baffle, distance between steel plane edge and baffle, inlet pressure, and gap between air knife and strip steel surface are investigated, and it is concluded that edge baffle can reduce over-coating and edge built-up.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 1994년도 추계학술대회 논문집
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• pp.590-596
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• 1994

In a CGL(Continuous Galvanizing Line) in steel making plants, zinc-coated steel sheets are produced. These sheets are used where long running corrosion resistivity is required. During the coating process top dross is produced, being harmful to the quality of the coating. To collect and remove this top dross, an automation system is developed consisting of a robot and its carriage system, a pot level sensor, a system controller, and specialtools. Forthe first, the level of the pot must be measured and fed back to the robot controller to avoid submersion of the robot hand in the hot pot. In this paper,acoustic and laser distance sensors are tested for the appropriate pot lvel sensor, especially the former in the view point of hot environment.

• Corrosion Science and Technology
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• 제10권2호
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• pp.43-46
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• 2011

Zinc consumption in a continuous galvanizing line is one of the highest operating cost items in the facility and minimizing zinc waste is a key economic objective for any operation. One of the primary sources of excessive loss of zinc is through the formation of top dross and skimmings in the coating pot. It has been reported that the top skimmings, manually removed from the bath, typically consist of more than 80% metallic zinc with the remainder being entrained dross particles ($Fe_2Al_5$) along with some oxides. Depending on the drossing practices and bath management, the composition of the removed top skimmings may contain up to 2 wt% aluminum and 1 wt% iron. On-going research efforts have been aimed at in-house recovery of the metallic zinc from the discarded top skimmings prior to selling to zinc recycling brokers. However, attempting to recover the zinc entrapped in the skimmings is difficult due to the complex nature of the intermetallic dross particles and the quality and volume of the recycled zinc is highly susceptible to fluctuations in processing parameters. As such, an efficient method to extract metallic zinc from top skimmings has been optimized through the use of a specialized thermo-mechanical process enabling a continuous galvanizing facility to conserve zinc usage on-site. Also, through this work, it has been identified that filtration of discrete dross particles has been proven effective at maintaining the cleanliness of the zinc. Future efforts may progress towards expanded utilization of filters in continuous galvanizing.