Because of the very large energy savings and increased production capacity, high-velocity-end-fired kettle furnaces, waste flue heat recovery, and lengthwise insulated clam kettle covers are likely to become common in hot dip galvanizing plants. The short payback period is obvious and once the equipment is paid for the savings become profit. In the future, kettle temperature is likely to be displayed near the kettle in large LED numbers along with a large LED timer. These displays will be in easy view of supervisors and workers alike who will learn to put them to good use. With this information and, when available, the "silicon equivalent" (as defined by Teck Cominco, which is a refinement of the Sandalin effect) from the "heat" of the steel, accurate kettle temperatures and kettle times can be determined to adjust zinc thickness to fit requirements. Over-ride-able and easily programmable kettle furnace controls (still with adequate safeguards) are likely to attain the required results. To attain thicker zinc coatings on the steel, a longer time in the zinc and/or a higher zinc bath temperature are required. This article contains theoretical and practical information about hot dip galvanizing furnaces. Very often each kettle furnace has unique requirements, thus a competent furnace designer, fabricator, and installer must be carefully chosen to attain the required results.
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