2004 GALVANIZING LINE MARKET STUDY

Transcription

1 2004 GALVANIZING LINE MARKET STUDY Final Report by: AIM Report No. 333

2 FOREWORD This Report was prepared by AIM Market Research. Neither AIM Market Research, nor any person acting on its behalf: a) makes any warranty, express or implied, with respect to the use of any information, apparatus, method, or process disclosed in this Report or that such use may not infringe privately owned rights; or b) assumes any liabilities with respect to the use of or for damages resulting from the use of, any information, apparatus, method, or process disclosed in this Report. AIM Market Research is a privately owned market research and development firm.. All rights reserved. This report or its contents either in whole or in part may not be reproduced, stored in a data retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise without the express written consent of AIM Market Research. Unauthorized and/or unlicensed copying of any part of this report or its appendices is in violation of copyright law. Page i

3 CONTENTS LIST OF APPENDICES... vi LIST OF FIGURES... ix LIST OF TABLES... xx EXECUTIVE SUMMARY... ES-1 PROSPECT ANALYSIS... S-1 CONCLUSIONS... C-1 INTRODUCTION... IN-1 Section 1 Characterizing the Plants & Galvanizing Lines Surveyed Part 1 Characterizing the Galvanizing Producer Metallic Coating Lines in the Plants Surveyed Characterizing the Galvanizing Lines Surveyed HDG Lines Surveyed & Number that Produce Galvanneal Start-up Year Type of Plant Orientation of HDG Lines Annealing Furnace Soaking Time Outside Processors Toll Processors Minimills Zinc Pot Size Integrated Steel Plants Outside Processors Minimills Pre-melt Pot Type of Zinc Pot Types of Power used for Galvanneal Furnaces Rated Capacity of Induction Heaters Galvanneal Soaking Zone Induction Furnace Soak Time Coating Pot Heater Orientation of Cleaning Section Post Treatment Coatings Type of Plant Method of Application Type of Plant Post Treatment Oven Type of Plant Wiper Type of Spangle Minimizer Page ii

4 Section 2 Galvanizing Lines Equipment Suppliers Major Mechanical Galvanizing Line Suppliers Major Electrical Equipment Supplier Auxiliary Equipment Welders Galvanizing Line Wipers Tension Leveler Skin-Pass Mills CPC Annealing Furnace Coating Pots Coil Banders Band Cutters Surface Defect Detectors Coating Weight Gauges Oilers Section 3 STEEL PRODUCTION OF GALVINIZING LINES SURVEYED 2003 Steel Production vs. Rated Capacity HDG Lines Steel Production versus Projected Increase Over Electro-galvanizing Lines HDG Production by Type of Metallic Coating Share of Production of HDG Lines by Type of Metallic Coating Galvanized Steel Production Galvannealed Steel Production Galvalume Steel Production Section 4 CHARACTERIZING THE GALVANIZING LINES SURVEYED Part 2 Operating Scenario of this Metallic Coating Line Type of Steel Substrate Galvanizied Toll Processed Production Source of Steel Substrate Dross Generation Product Dimensions Strip Thickness Strip Width PIW Zinc Bath Assay Aluminum Content Lead Content Page iii

5 Section 5 LINE SPEEDS & END USE MARKETS OF GALVANIZING LINES SURVEYED Line Speed Galvanized Exposed Automotive Galvanealed Exposed Galvanized Unexposed Galvannealed Unexposed What Mostly Limits Galvanizing Speed Major End-Use Markets of Galvanized Products End-Use Market Share for Galvanized Product Section 6 GALVANIZING LINE COST ELEMENTS, FUNDAMENTAL PRIORITIES, ADEQUACY OF EXISTING EQUIPMENT, FUTURE GRADES CONSIDERED Comparing the Impact of Various Galvanizing Line Cost Elements The Fundamental Priority The Adequacy of Galvanizing Facilities The Adequacy of Present Galvanizing facilities Self Accident Diagnosis Limits to Increasing Production on Existing Line The Reasons for Rejection, Reclassification, or Re-designation of Finished Coils Future Steel Grades Considered for Galvanizing Production Adequacy of the Galvanizing Line and APC Cooling Equipment Adequacy of the Furnace and APC Cooling System Does the APC Strip Cooling System Provide Adequate Cooling and Strip Stability Problems, Concerns, and Issues with Galvanizing Furnace and APC Cooling System New Technologies Considered Interest in Service from Plate Heat Exchanger OEM Section 7 GALVANIZING BATH CHEMISTRY CONTROL Transitions from Galvanneal to Galvanize Transition Time The Importance of Reducing Transition Time Duration of Galvanneal Production Between GA/GI Transitions Alloys or Techniques Used to Modify the Chemistry of the Galvanizing Bath lbs. Transition Brightener Strip Jumbo Aluminum Brightener Bars Other Alloys Interest in New Technologies to Add Aluminum to Facilitate Faster Transitions Page iv

6 Section 8 ZINC CONSUMPTION & NOMINAL CHEMISTRY Zinc Metal Consumption The Use & Composition of SHG & CGG Grade Zinc The Composition of SHG Grade Zinc Aluminum Content Lead Content CGG Grade Zinc Aluminum Content Lead Content Antimony Content Zinc Sulfate Use by EGL Lines Section 9 COATING WEIGHTS OF GALVANIZING LINES SURVEYED Coating Weight Galvanizing Coating Weight Galvanneal Coating Weight Al-Zn Coating Weight EGL Coating Weight Measuring and Controlling Coating Pot Chemistry Measuring Coating Pot Chemistry Controlling Coating Pot Chemistry Section 10 DROSS GENERATION & PLANS/CONSIDERATIONS TO UPGRADE, REPLACE OR ADD GALVANIZING FACILITIES Dross Generation Top Dross Removal & Disposition LME Value of Dross Term of Dross Contract Dross Removal Method Number of Workers Used for Dross Removal Analysis of Top Dross Plans to Add or Upgrade Galvanizing Equipment Outside Combustion Consulting Service Page v

7 LIST OF APPENDICES Appendix 1: Appendix 2: Appendix 3: Appendix 4: Appendix 5: Appendix 6: Appendix 7: Appendix 8: Appendix 9: Appendix 10: Appendix 11: Appendix 12: Appendix 13: Appendix 14: Appendix 15: Appendix 16: Appendix 17: Appendix 18: Appendix 19: Appendix 20: Appendix 21: Appendix 22: Appendix 23: Appendix 24: List of Firms Contacted individuals Contacted and interviewed Prospect Analysis Characterizing the Galvanizing Producer Characterize the Galvanizing Line Characterize the Galvanizing Line (cont.) Post Treatment and Spangle Minimizer Galvanizing Line Equipment Suppliers Characterizing Production of the Metallic Coating Line Operating Hours, Source of Steel Processed, Dross Rate Product Dimensions and Bath Assays Line Speed Major End-Use Markets and Relative Impact of Cost Elements Fundamental Priority of Galvanizing Line Adequacy of the Galvanizing Line Equipment, Maintenance, and Limitations to increasing Production Reasons for Rejection or Downgrading of Coils Future Steel Grades for Galvanizing Product and Adequacy of Equipment Adequacy of Furnace and APC Cooling System Plans to Upgrade and Objectives Key Decision Makers and New Technologies Considered for the APC Cooling Equipment interest in Service by an OEM Heat Exchanger Manufacturer Galvanizing Bath Chemistry Control Galvanizing Bath Chemistry Control (cont.) The Importance of Reducing Transition Time and interest in New Facilitating Technology Page vi

8 Appendix 25: Appendix 26: Appendix 27: Appendix 28: Appendix 29: Appendix 30: Appendix 31: Appendix 32: Appendix 33: Appendix 34: Appendix 35: Appendix 36: Appendix 37: Appendix 38: Appendix 39: Appendix 40: Appendix 41: Reprocessing Galvanized Steel Coils LIST OF APPENDICES (Cont.) Zinc Metal Consumption Other Elements Specified in the ingot Range of Coating Weight Chemistry Measurement / Control System Unresolved Problems and Issues Top Dross Generation, Disposition, and Removal Toll Processing Dross Removal Dross Removal Process and Equipment Analysis of Top Dross and Comments Plans or Considerations for Galvanizing or Related Lines Bath Chemistry (For EGL) Plans to Modify Bath Chemistry Measurement and Control interest in Consulting Services Questionnaire for North American Galvanizing Line Market Study List of Non-Participants Page vii

9 LIST OF FIGURES INTRODUCTION Figure 1 - Figure 2 - Figure 3- Functional Areas individuals interviewed...in-3 Types of Plants Surveyed...IN-4 Location of 56 Galvanizing Lines Surveyed by Location...IN-4 SECTION 1 - CHARACTERIZING THE PLANTS & GALVANIZING LINES SURVEYED PART 1 Figure 4 - Types of Metallic Coating Lines in Plants Surveyed Figure 5 - Figure 6 - Figure 7 - Figure 8 - Figure 9 - HDG Lines Surveyed & Number That Also Galvanneal Decade in Which HDG Lines Surveyed Started Up - Overall When HDG Lines Started Up by Type of Plant Orientation of HDG Lines Surveyed Annealing Furnace Soak Time of integrated Steel Producer s HDG Lines Figure 10 - Annealing Furnace Soak Time of Outside Processor s HDG Lines Figure 11 - Annealing Furnace Soak Time of Toll Processor s HDG Lines Figure 12 - Annealing Furnace Soak Time of Minimill s HDG Lines Figure 13 - Figure 14 - Pot Size of integrated Steel Producer s HDG Lines Pot Size of Outside Processor s HDG Lines Figure 15 - Pot Size of Toll Processor s HDG Lines Figure 16 - Pot Size of Minimill s HDG Lines Figure 17 - Is There A Pre-Melt Pot in HDG Lines Surveyed Figure 18- Figure 19 - Type of Zinc Pot in HDG Lines Surveyed Type of Galvanneal Furnace in HDG Lines Surveyed Page viii

10 LIST OF FIGURES (Cont.) SECTION 1 - CHARACTERIZING THE PLANTS & GALVANIZING LINES SURVEYED PART 1 (CONT.) Figure 20 - Power Ratings of induction Heated Galvanneal Furnaces Figure 21 - Gas Fired Galvanneal Furnace Soak Time Figure 22 - Induction Heated Galvanneal Furnace Soak Time Figure 23 - Orientation of Cleaning Sections of HDG Lines Surveyed Figure 24 - Post Treatment of Galvanizing Lines Surveyed - Overall Figure 25 - Post Treatment of Galvanizing Lines Surveyed by Type of Plant Figure 26 - Treatment Application Method Used by Galvanizing Lines Surveyed - Overall Figure 27 - Figure 28 - Figure 29 - Treatment Application Method Used by Galvanizing Lines Surveyed by Type of Plant Type of Post Treatment Oven Used by Galvanizing Lines Surveyed - Overall1-14 Type of Post Treatment Oven Used by Galvanizing Lines Surveyed by Type of Plant Section 2 GALVANIZING LINE EQUIPMENT SUPPLIERS Figure 30 - Figure 31 - Figure 32 - Figure 33 - Figure 34 - Major Mechanical Equipment Suppliers Identified by Galvanizing Lines Surveyed - Overall Major Mechanical Equipment Suppliers Identified by Galvanizing Lines Surveyed by Type of Plant Major Electrical Equipment Suppliers Identified by Galvanizing Lines Surveyed - Overall Major Electrical Equipment Suppliers Identified by Galvanizing Lines Surveyed Major Wiper Suppliers Identified by Galvanizing Lines Surveyed by Type of Plant Page ix

11 LIST OF FIGURES (Cont.) Section 2 GALVANIZING LINE EQUIPMENT SUPPLIERS (CONT.) Figure 35 - Major Tension Leveler Suppliers Identified by Galvanizing Lines Surveyed - Overall Figure 36 - Figure 37 - Figure 38 - Figure 39 - Figure 40 - Figure 41 - Figure 42 - Figure 43 - Figure 44 - Figure 45 - Major Tension Leveler Suppliers Identified by Galvanizing Lines Surveyed by Type of Plant Major Skin Pass Mill Suppliers Identified by Galvanizing Lines Surveyed Major CPC Suppliers Identified by Galvanizing Lines Surveyed Major Annealing Furnace Suppliers Identified by Galvanizing Lines Surveyed - Overall Major Annealing Furnace Suppliers Identified by Galvanizing Lines Surveyed by Type of Plant Major Coating Pot Suppliers Identified by Galvanizing Lines Surveyed Major Coating Weight Gauge Suppliers Identified by Galvanizing Lines Surveyed - Overall Major Coating Weight Gauge Suppliers Identified by Galvanizing Lines Surveyed by Type of Plant Major Oiler Suppliers Identified by Galvanizing Lines Surveyed - Overall Major Oiler Suppliers Identified by Galvanizing Lines Surveyed by Type of Plant Section 3 STEEL PRODUCTION OF GALVANIZING LINES SURVEYED Figure 46 - Figure 47 - Figure 48 - Figure Production Vs. Rated Capacity of Galvanizing Lines in integrated Steel Plants Surveyed Production Vs. Rated Capacity of Galvanizing Lines in Outside Processors Surveyed Production Vs. Rated Capacity of Galvanizing Lines in Toll Processor Plants Surveyed Production Vs. Rated Capacity of Galvanizing Lines in Minimills Surveyed Page x

12 Figure Production Vs. Rated Capacity of Electro-Galvanizing Lines in Plants Surveyed Page xi

13 LIST OF FIGURES (Cont.) Section 3 STEEL PRODUCTION OF GALVANIZING LINES SURVEYED (CONT.) Figure 51 - Figure 52 - Figure 53 - Figure 54 - Figure 55 - Figure 56 - Figure 57 - Figure 58 - Figure 59 - Projected 2004 Production Vs. increase 2004 Over 2003 of integrated Steel Galvanizing Lines Projected 2004 Production Vs. increase 2004 Over 2003 of Outside Processor Galvanizing Lines Projected 2004 Production Vs. increase 2004 Over 2003 of Toll Processor Galvanizing Lines Projected 2004 Production Vs. increase 2004 Over 2003 of Minimill Galvanizing Lines Projected 2004 Production Vs. increase 2004 Over 2003 of Electro- Galvanizing Lines Galvanize-Galvanneal Share of Production of HDG Lines in integrated Plants Galvanize-Galvanneal-Galvalume Share of Production of HDG Lines in Outside Processor Plants Galvanize-Galvanneal-Galvalume Share of Production of HDG Lines in Toll Processor Plants Galvanize-Galvanneal-Galvalume Share of Production of HDG Lines in Minimill Plants Figure Galvanized Steel Production by integrated Steel Plants Figure 61 - Figure Galvanized Steel Production by Outside Processor Plants Galvanized Steel Production by Toll Processors Figure Galvanized Steel Production by Minimills Figure Galvanneal Production by integrated Steel Plants Surveyed Figure Galvanneal Production by Outside Processor Plants Surveyed Figure 66 - Figure 67 - Figure Galvanneal Production by Toll Processors Surveyed Galvanneal Production by Minimills Surveyed Galvalume Production by Plant Surveyed Page xii

14 LIST OF FIGURES (Cont.) Section 4 CHARACTERIZING THE GALVANIZING LINES SURVEYED PART 2 Figure 69 - Days Per Week Operating Scenario of Galvanizing Lines Surveyed Figure 70 - Weeks Per Year Operating Scenario of Galvanizing Lines Surveyed Figure 71 - Turns Per Week Operating Scenario of Galvanizing Lines Surveyed Figure 72 - Figure 73 - Share of Galvanizing Lines Surveyed That Process Cold Rolled Steel Cold Rolled Share of Steel Substrate Galvanized by Plants Surveyed Figure 74 - Toll Processed Share of EGL Steel Production Figure 75 - Toll Processed Share of HDG Steel Processed by Toll Processors Figure 76 - Figure 77 - Figure 78 - Source of Steel Substrate Processed by Galvanizing Lines Surveyed Top Dross Generated by integrated Steel HDG Lines Surveyed Top Dross Generated by Other HDG Lines Surveyed Figure 79 - Strip Thickness Processed by integrated Galvanizing Lines Surveyed Figure 80 - Figure 81 - Strip Thickness Processed by Outside Processor Galvanizing Lines Surveyed Strip Thickness Processed by Toll Processor Galvanizing Lines Surveyed Figure 82 - Strip Thickness Processed by Minimill Galvanizing Lines Surveyed Figure 83 - Strip Widths Processed by integrated Galvanizing Lines Surveyed Figure 84 - Strip Widths Processed by Outside Processor Galvanizing Lines Surveyed Figure 85 - Figure 86 - Figure 87 - Figure 88 - Figure 89 - Strip Widths Processed by Toll Processor Galvanizing Lines Surveyed Strip Widths Processed by Minimill Galvanizing Lines Surveyed PIW of integrated Galvanizing Lines Surveyed PIW of Other Galvanizing Lines Surveyed Aluminum Content in Bath Assay in integrated Galvanizing Lines Surveyed Page xiii

15 Figure 90 - Aluminum Content in Bath Assay in Outside Processor Galvanizing Lines Surveyed LIST OF FIGURES (Cont.) Section 4 CHARACTERIZING THE GALVANIZING LINES SURVEYED PART 2 (CONT.) Figure 91 - Aluminum Content in Bath Assay in Toll Processor Galvanizing Lines Surveyed Figure 92 - Aluminum Content in Bath Assay in Minimill Galvanizing Lines Surveyed Figure 93 - Lead Content in Bath Assay in integrated & Other Galvanizing Lines Surveyed Section 5 LINE SPEED & END-USE MARKETS OF GALVANIZING LINES SURVEYED Figure 94 - Figure 95 - Figure 96 - Exposed Automotive Line Speed of EGL Lines Surveyed Exposed Automotive Line Speed of Hot Dipped Galvanized Lines Surveyed Exposed Automotive Line Speed of Hot Dipped Galvanneal Lines Surveyed Figure 97 - Unexposed Automotive Line Speeds of integrated HDG Lines Surveyed Figure 98 - Figure 99 - Unexposed Automotive Line Speeds of Outside Processor HDG Lines Surveyed Unexposed Automotive Lines Speeds of Toll Processor HDG Lines Surveyed Figure Unexposed Automotive Lines Speeds of Minimill HDG Lines Surveyed Figure Unexposed Automotive Galvannealed Steels Line Speed of integrated HDG Lines Surveyed Figure Unexposed Automotive Galvannealed Steels Line Speed of Other HDG Lines Surveyed Figure What Limits Galvanizing Speed? by Galvanizing Lines Overall Figure What Limits Galvanizing Speed? by Galvanizing Lines Surveyed by Type of Plant Figure Major End-Use Markets of Galvanizing Lines Surveyed - Overall Page xiv

16 Figure Major End-Use Markets of Galvanizing Lines Surveyed by Type of Plant Page xv

17 LIST OF FIGURES (Cont.) Section 5 LINE SPEED & END-USE MARKETS OF GALVANIZING LINES SURVEYED (CONT.) Figure Major End-Use Markets of Galvanizing Lines Surveyed Overall Figure Major End-Use Markets of integrated Galvanizing Lines Surveyed Figure Major End-Use Markets of Outside Processor Galvanizing Lines Surveyed Figure Major End-Use Markets of Toll Processor Galvanizing Lines Surveyed Figure Major End-Use Markets of Minimill Galvanizing Lines Surveyed Section 6 GALVANIZING LINE COST ELEMENTS, FUNDAMENTAL PRIORITIES, ADEQUACY OF EXISTING EQUIPMENT, FUTURE GRADES CONSIDERED Figure The Relative Impact of Various Cost Elements in The Galvanizing Operation - Overall Figure Rating The Relative Impact of Various Cost Elements in The Galvanizing Operation in integrated Steel Plants Surveyed Figure The Relative Impact of Various Cost Elements in The Galvanizing Operation in Outside Processors Surveyed Figure The Relative Impact of Various Cost Elements in The Galvanizing Operation in Toll Processors Surveyed Figure The Relative Impact of Various Cost Elements in The Galvanizing Operation in Minimills Surveyed Figure The Fundamental Priorities of Galvanizing Lines Surveyed - Overall Figure The Fundamental Priorities of Galvanizing Lines Surveyed by Type of Plant Figure What (At Present) Limits increasing Production of Galvanizing Lines Surveyed - Overall Figure What (At Present) Limits increasing Production of Galvanizing Lines by Type of Plant Figure The Reason For Downgrading Finished Coils Figure Different Steel Grades Now Processed, Trialed, Or Expected To Be Processed by integrated Steel Plants Within 2 To 5 Years Page xvi

18 LIST OF FIGURES (Cont.) Section 6 GALVANIZING LINE COST ELEMENTS, FUNDAMENTAL PRIORITIES, ADEQUACY OF EXISTING EQUIPMENT, FUTURE GRADES CONSIDERED (CONT.) Figure Rating The Adequacy of The Existing Furnace & APC Cooling Systems Figure Does APC (After Pot Cooling) System Provide Adequate Cooling & Stability? Figure Galvanizing Lines With Problems, Issues Or Concerns Section 7 GALVANIZING BATH CHEMISTRY CONTROL Figure Galvanizing Lines That Make Transitions Between Galvanneal & Galvanize Processing Figure Galvanneal to galvanize transition time indicated by integrated plants surveyed Figure Galvanneal to galvanize transition time indicated by other plants surveyed Figure How important (0-10) would it be to reduce transition time - overall Figure 130 Figure 131 Average cycle between galvanneal to galvanize transition by integrated plants surveyed Average cycle between galvanneal to galvanize transition by other plants surveyed Figure 132- Is a 2400 Lbs. transition brightener strip jumbo of interest Figure 133- What % Aluminum Brightener Bars are used to Modify the Chemistries - Overall Figure 134- What % Aluminum Brightener Bars are Used to Modify the Chemistries by Type of Plant Figure 135 Interested in New Technologies to Add Aluminum to Facilitate Faster Transitions? Page xvii

19 LIST OF FIGURES (Cont.) Section 8 ZINC METAL CONSUMPTION & NOMINAL CHEMISTRY Figure 136 Figure 137 Figure 138 Figure 139 Figure 140 Share of Zinc Metal Consumption by Galvanizing Lines surveyed by type of plant Annual Zinc Metal Consumption by Galvanizing Lines in integrated plants surveyed Annual Zinc Metal Consumption by Galvanizing Lines in Outside Processor Plants Surveyed Annual Zinc Metal Consumption by Galvanizing Lines in toll processor plants surveyed Zinc Metal Consumption by Galvanizing Lines in Minimill Plants Surveyed Figure 141- The Use of Either SHG Or CGG Grades of Zinc by Galvanizing Lines Surveyed Figure 142- SHG Zinc Metal Annual Consumption by Galvanizing Lines in integrated Plants Surveyed Figure 143- SHG Zinc Metal Annual Consumption by Galvanizing Lines in Other Plants Surveyed Figure 144- Aluminum Content of SHG Zinc consumed by Galvanizing Lines in integrated Plants Surveyed Figure 145 Figure 146 Figure 147 Figure 148 Figure 149 Aluminum Content of SHG Zinc Consumed by Galvanizing Lines in Other Plants Surveyed Lead Content of SHG Zinc Consumed by Galvanizing Lines in Plants Surveyed CGG Zinc Metal Annual Consumption by Galvanizing Lines in integrated Plants Surveyed CGG Zinc Metal Annual Consumption by Galvanizing Lines in Other Plants Surveyed Aluminum Content of CGG Zinc Consumed by Galvanizing Lines in integrated Plants Surveyed Figure 150- Aluminum Content of CGG Zinc Consumed by Galvanizing Lines in Outside Processor Plants Surveyed Page xviii

20 LIST OF FIGURES (Cont.) Section 8 ZINC METAL CONSUMPTION & NOMINAL CHEMISTRY(CONT.) Figure 151 Aluminum Content of CGG Zinc Consumed by Galvanizing Lines in Toll Processor Plants Surveyed Figure 152- Aluminum Content of CGG Zinc Consumed by Galvanizing Lines in Minimill Plants Surveyed Figure 153- Lead Content of CGG Zinc Consumed by Galvanizing Lines in Plants Surveyed Figure 154- Antimony Content of Zinc Consumed by Galvanizing Lines in Minimill Plants Surveyed Section 9 COATING WEIGHTS OF GALVANIZING LINES SURVEYED Figure Zinc Coating Weights Produced by integrated Steel Plant Galvanizing Lines Surveyed Figure Zinc Coating Weights Produced by Outside Processor Galvanizing Lines Surveyed Figure Zinc Coating Weights Produced by Toll Processor Galvanizing Lines Surveyed Figure Zinc Coating Weights Produced by Minimill Galvanizing Lines Surveyed Figure Galvanneal Coating Weights Produced by HDG Galvanizing Lines Surveyed Figure How The Galvanizing Lines Surveyed Measure Coating Pot Chemistry Figure How The Galvanizing Lines Surveyed Control Pot Chemistry Section 10 DROSS GENERATION & PLANS/CONSIDERATIONS TO UPGRADE, REPLACE OR ADD GALVANIZING FACILITIES Figure Annual Top Dross Generated by Galvanizing Lines in Integrated Plants Surveyed Figure Annual Top Dross Generated by Galvanizing Lines in Outside Processor Plants Surveyed Page xix

21 Figure Annual Top Dross Generated by Galvanizing Lines in Toll Processor Plants Surveyed Page xx

22 LIST OF FIGURES (Cont.) Section 10 DROSS GENERATION & PLANS/CONSIDERATIONS TO UPGRADE, REPLACE OR ADD GALVANIZING FACILITIES (CONT.) Figure Annual Top Dross Generated by Galvanizing Lines in Minimills Surveyed Figure The Firm That Their Dross Is Sold To As indicated by Galvanizing Lines Surveyed Figure Share of Lines Surveyed That Said Drossing Is A Dangerous Job Figure Number of Workers Used For Drossing indicated by Galvanizing Lines Surveyed Figure Share of Plants Surveyed That indicated Plans Or Considerations To Upgrade, Replace,Or Add Galvanizing Lines Page xxi

23 PROSPECT ANALYSIS LIST OF TABLES Table A - Summary of Prospects... S-1 Table B - Best Prospects... S-1 Section 1 CHARACTERIZING THE PLANTS & GALVANIZING LINES SURVEYED Table 1 - Metallic Coating Lines in Plants Surveyed Section 3 STEEL PRODUCTION OF GALVANIZING LINES SURVEYED Table 2 - Production of Galvanizing Lines Surveyed Table Galvanizing Production by Type of Metallic Coating Table Production by Type of Galvanizing Lines Surveyed Table 5 - Galvanizing Lines with inadequate Furnace & APC Cooling Equipment Table 6 - Furnace & APC Cooling is Not Adequate Table 7 - Problem, Issue or Concern with Existing Furnace or APC System Table 8 - Plants that Plan to Improve Furnace or APC System & Objective Table 9 - The Importance of Reducing Transition Time Table 10 - Plants interested in 2400 Lbs. Transition Brightener Strip Jumbos Table 11 - Table 12 - Table 13 - Table Dross Generation by Type of Plant Surveyed Plan or Considerations to Upgrade Galvanizing Facilities in integrated Plants Plan or Considerations to Upgrade Galvanizing Facilities in Outside Processors Plan or Considerations to Upgrade Galvanizing Facilities in Toll Processors & Minimills Table 15 - Plants interested in Outside Combustion Consulting Services Page xxii

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