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Galvanizing and Water Treatment Optimization Course
More than 2 million students worldwide

Galvanizing and Water Treatment Optimization Course

Master the technical and operational skills needed to run galvanising and water treatment processes at peak efficiency. This course covers everything from zinc bath chemistry and surface preparation to coagulation, filtration, and effluent compliance. You will leave with practical tools to reduce costs, cut waste, and meet regulatory standards.

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What you will learn:

You will build a complete understanding of hot-dip galvanising and industrial water treatment, from foundational chemistry to advanced process control. The course covers surface preparation, zinc bath management, coagulation, filtration, membrane technologies, and disinfection systems. You will apply statistical process control, design of experiments, and root cause analysis to real operational problems. Environmental compliance, water reuse, and closed-loop system design are also addressed. By the end, you will be equipped to develop and execute plant-wide optimisation plans that deliver measurable results in quality, cost, and sustainability.

How you study in practice Galvanizing and Water Treatment Optimization Course

How you practise Galvanizing and Water Treatment Optimization Course

For companies looking to train their teams

With Dedika for businesses, the course includes exercises and examples tailored to your company and its specific needs.

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Course content

8 Chapters • 40 LessonsDuration between 4 and 360 hours (you decide)

Chapter 1See details

Foundations of Galvanizing and Water Treatment

  • Lesson 1 • Water Treatment Process Overview

    Outlines coagulation, filtration, and disinfection as sequential treatment stages. Links each stage to water quality targets.

  • Lesson 2 • Galvanizing Process Overview

    Maps the full galvanizing sequence from surface preparation to quench. Establishes process flow as the framework for optimisation study.

  • Lesson 3 • Metallurgy of Zinc Coating

    Covers iron-zinc reaction kinetics and alloy layer formation. Connects steel substrate properties to coating quality outcomes.

  • Lesson 4 • Water Chemistry Fundamentals

    Introduces pH, alkalinity, hardness, and dissolved solids as control parameters. Provides the chemical baseline for all treatment decisions.

  • Lesson 5 • Key Performance Indicators

    Defines measurable KPIs for both galvanizing yield and water treatment efficiency. Grounds optimisation goals in quantifiable benchmarks.

Chapter 2See details

Surface Preparation and Pre-Treatment Control

  • Lesson 1 • Degreasing Bath Management

    Examines caustic concentration, temperature, and contamination load in degreasing tanks. Proper control prevents oil carry-over into pickling.

  • Lesson 2 • Acid Pickling Optimisation

    Analyses hydrochloric acid concentration, iron content, and inhibitor dosing for efficient scale removal. Balances steel loss against cleaning effectiveness.

  • Lesson 3 • Rinsing and Drag-Out Control

    Covers counter-current rinsing design and drag-out volume reduction. Minimises chemical carry-over between pre-treatment stages.

  • Lesson 4 • Flux Bath Chemistry

    Details zinc ammonium chloride flux composition and its role in oxide removal before immersion. Flux quality directly affects ash generation and coating defects.

  • Lesson 5 • Pre-Treatment Wastewater Handling

    Addresses neutralisation, heavy metal precipitation, and sludge dewatering from pre-treatment effluents. Connects pre-treatment control to environmental compliance.

Chapter 3See details

Zinc Bath Operation and Control

  • Lesson 1 • Immersion Parameters and Withdrawal

    Covers immersion angle, speed, and withdrawal rate as determinants of coating thickness and drainage. Optimised parameters reduce runs and bare spots.

  • Lesson 2 • Temperature Control and Energy Use

    Analyses bath temperature ranges, heat loss sources, and burner efficiency. Stable temperature reduces dross formation and energy cost.

  • Lesson 3 • Dross Formation and Removal

    Identifies bottom dross and top dross causes, composition, and removal schedules. Dross control directly lowers zinc consumption and surface defects.

  • Lesson 4 • Zinc Consumption Benchmarking

    Establishes zinc-per-ton metrics and loss attribution across bath, dross, and ash. Benchmarking identifies the highest-impact reduction opportunities.

  • Lesson 5 • Bath Composition Management

    Examines zinc purity, aluminium, lead, and bismuth additions and their effects on coating properties. Alloy balance determines surface finish and fluidity.

Chapter 4See details

Coagulation, Flocculation, and Sedimentation

  • Lesson 1 • Jar Test Methodology

    Teaches jar test procedure for coagulant dose and pH optimisation before full-scale application. Results translate directly to chemical feed setpoints.

  • Lesson 2 • Coagulant Chemistry and Selection

    Compares alum, ferric salts, and polymer coagulants by charge neutralisation and sweep floc mechanisms. Selection depends on raw water quality and cost.

  • Lesson 3 • Sedimentation and Clarifier Performance

    Covers surface overflow rate, sludge blanket depth, and tube settler efficiency. Clarifier optimisation reduces effluent turbidity and filter loading.

  • Lesson 4 • Flocculation Basin Design

    Analyses G-value, retention time, and tapered energy input for floc growth. Proper design prevents floc shear and improves settler loading.

  • Lesson 5 • Chemical Feed System Control

    Addresses dosing pump calibration, flow-paced control, and online turbidity feedback. Automated dosing reduces chemical waste and operator variability.

Chapter 5See details

Filtration and Membrane Technologies

  • Lesson 1 • Microfiltration and Ultrafiltration

    Introduces MF and UF membrane pore sizes, flux rates, and fouling mechanisms. These technologies replace conventional clarification in compact systems.

  • Lesson 2 • Membrane Fouling and Cleaning

    Identifies scaling, biofouling, and colloidal fouling and their chemical cleaning remedies. Fouling control extends membrane life and maintains flux.

  • Lesson 3 • Backwash Optimisation

    Covers backwash flow rate, air scour, and collapse-pulsing to restore filter capacity. Optimised backwash reduces water waste and media loss.

  • Lesson 4 • Reverse Osmosis Fundamentals

    Explains osmotic pressure, salt rejection, and recovery rate in RO systems. RO enables high-purity water production for sensitive process applications.

  • Lesson 5 • Granular Media Filter Design

    Examines filter media selection, bed depth, and filtration rate for turbidity removal. Media properties determine run length and backwash frequency.

Chapter 6See details

Disinfection and Effluent Quality Control

  • Lesson 1 • Effluent Monitoring and Reporting

    Establishes online sensor networks, grab sampling schedules, and compliance reporting workflows. Continuous monitoring enables rapid response to quality exceedances.

  • Lesson 2 • Industrial Effluent Treatment

    Addresses heavy metal removal, pH adjustment, and cyanide destruction for galvanizing wastewater. Treated effluent must meet discharge quality thresholds.

  • Lesson 3 • Disinfection Byproduct Management

    Identifies trihalomethane and haloacetic acid formation pathways and precursor removal strategies. Byproduct control protects public health and regulatory standing.

  • Lesson 4 • Chlorination Chemistry and Control

    Covers free and combined chlorine chemistry, breakpoint chlorination, and CT concept. Chlorine dose is balanced against disinfection byproduct formation.

  • Lesson 5 • Alternative Disinfection Methods

    Compares UV irradiation, ozonation, and chloramine systems by efficacy and byproduct profile. Selection depends on source water quality and distribution needs.

Chapter 7See details

Process Optimisation Techniques

  • Lesson 1 • Continuous Improvement Frameworks

    Applies PDCA and DMAIC cycles to sustain optimisation gains over time. Structured frameworks embed improvement into daily operations.

  • Lesson 2 • Root Cause Analysis Methods

    Applies fishbone diagrams, five-why analysis, and fault tree analysis to process failures. Structured RCA prevents recurrence of quality and efficiency losses.

  • Lesson 3 • Statistical Process Control

    Introduces control charts, capability indices, and run rules for process stability assessment. SPC converts routine data into actionable quality signals.

  • Lesson 4 • Energy and Chemical Auditing

    Structures energy balance and chemical mass balance audits to locate waste streams. Audit findings prioritise cost reduction and sustainability initiatives.

  • Lesson 5 • Design of Experiments

    Covers factorial and response surface designs for optimising multiple process variables simultaneously. DOE reduces trial-and-error and quantifies factor interactions.

Chapter 8See details

Advanced Integration and Strategic Management

  • Lesson 1 • Environmental Compliance Strategy

    Aligns process controls with discharge limits, air emission standards, and waste classification rules. Proactive compliance reduces regulatory risk and shutdown exposure.

  • Lesson 2 • Water Reuse and Closed-Loop Systems

    Designs water recycling circuits that link treatment output to galvanizing pre-treatment input. Closed-loop systems reduce freshwater intake and effluent volume.

  • Lesson 3 • Automation and Process Control Integration

    Covers SCADA, PLC-based control loops, and sensor integration for both process areas. Automation reduces variability and enables real-time optimisation.

  • Lesson 4 • Strategic Optimisation Planning

    Builds a multi-year optimisation roadmap linking KPIs, projects, and resource allocation. The plan translates technical findings into executive-level decisions.

  • Lesson 5 • Total Cost of Ownership Analysis

    Calculates capital, operating, and maintenance costs across the integrated system. TCO analysis guides investment decisions for process upgrades.

Certification

Your valid completion certificate

This course is for you:

  • Galvanising plant operator: ready to move beyond routine tasks into optimization.

  • Water treatment technician: seeking deeper process control knowledge and career growth.

  • Industrial process engineer: managing both coating and water systems at one facility.

  • Environmental compliance officer: needing stronger technical grounding in treatment operations.

  • Maintenance supervisor: wanting to reduce downtime through smarter process management.

  • Recent engineering graduate: entering the galvanising or water treatment industry for the first time.

What our students say

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Giulio CarloDigital Marketing Student
I like how the lessons are straight to the point and how I can change chapters and skip content I don't need.
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I like the content and the way videos are presented and transcribed, which speeds up the process!
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Luciana AlvarengaNail Design Student
The platform is fast, simple to use. The diversity of content and complementary videos really help with learning.
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