During zinc coating processes, not all sprayed zinc necessarily reaches the intended surface. Fine zinc particles can remain entrained in the surrounding air and must be captured efficiently to limit material loss and contamination.
FlowMotion used CFD to analyse the airflow and particle transport in the extraction and separation system. The continuous air phase was calculated together with the trajectories of zinc particles released into the flow.
A particle trajectory is governed by its size and density, the local air velocity, the relative velocity between particle and air, and the resulting aerodynamic drag. Inertia and gravity can cause larger particles to deviate substantially from the surrounding airflow.
The simulations showed where zinc overspray was transported and how effectively different geometries captured or separated the particles. Regions of recirculation or insufficient extraction could be identified directly.
This provided a basis for improving zinc recovery and reducing unwanted particle emissions from the process.
