Reduction of zinc consumption with enhanced corrosion protection in hot-dip galvanized coatings: A process-based cost analysis

To improve sustainability in a hot-dip galvanized coating industry, a series of galvanizing techniques have been developed. Here, a relatively novel galvanizing technique developed to reduce zinc consumption and enhance steel's corrosion protection is investigated in relation to the conventional galvanizing technique. A process-based cost modeling (PBCM) is employed to analyze the process's cost effectiveness and to determine the influence of the cost drivers, including part surface area, coating thickness, and raw materials’ costs. The new process, which involves the use of either electrodeposition or electroless-deposition technique, is found economically attractive if the electrodeposition technique is integrated and the pre-coating layer remains thin. The electroless-deposition integrated process shows promise as zinc and nickel prices increase. Cost reduction of the galvanizing process with pre-coating layers is achieved mainly through reduction of zinc consumption and exclusion of the fluxing step.

► We analyze economic viability of innovative galvanizing process for reduction of zinc consumption, using process-based cost model.
► The new galvanizing process allows reduction of zinc consumption by 74% while providing enhanced corrosion protection.
► When thickness of pre-coat is controlled below a few micrometers, the new process is economically feasible regardless of zinc price.
► The new process involving electrodeposition is more economically feasible than that with electroless deposition.