Electric Immersion Heated Ceramic Kettles for

Galvanized and Galfan Coated Steel Wire

Sizes: From 1.5Mts long x 0.6Mts Wide x 0.65 Mts deep

Up to8.0Mts long x 1.5 Mts Wide x 1.2 Mts deep.

(Individually designed to meet customer’s specifications in respect of number of wires, wire tonnage and DV).

These kettles have a ridged steel body to ensure support for the one part ceramic lining. The ceramic lining is plasticized to reduce the risk of cracking. Energy consumption is reduced by use of insulation between the ridged steel frame and the outer decorative metal skin. Kettle exterior temperature is normally 40/45°C. The appearance is modern, clean and tidy.

The kettle can be fitted with a counterbalanced, insulated cover to reduce heat loss and energy consumption while ensuring ease of wire replacement.

These kettles are designed to take vertical and inclined headwork to carry wiping and quench equipment.

All wire kettles have an inclined internal base to reduce the mass if zinc used to fill the kettle to the operating level.

They are fitted with a long lasting ceramic sinker roller which can be positioned to suit.

These kettles are delivered needing only a flat concrete base, connection to a 380V 3 phase electric supply and 4 to 7 days high temperature “cooking” prior to commencing melting of zinc. A life of 10 to 20 years is practical.

The absence of iron in the ceramic lining makes it practical to run a low dross or zero dross galvanizing system when the kettles are used with the WICA Galvanizing patented pre-flux system or pre-flux iron reduction system. WICA galvanizing operates its own Galfan coating line on a zero dross basis using such equipment.

The combination of ceramic kettle and patented WICA Galvanizing pre-flux system makes it possible to run a single kettle Galfan system.

The electrical control system is sophisticated having the following features

¨ Variable power input depending on bath temperature variance from set point

¨ Over temperature protection of heating elements

¨ Fault indication

Two types of Electric heating are available

Ceramic electric heated

These heaters are flat sided and line the edge of the kettle to give a uniform heat throughout the kettle. The heating control ensures close adherence to the desired temperature. It is generally practical to maintain the kettle at ±3°C of the desired temperature.

These heaters are manufactured with a ceramic sheath (high pressure formed to increase heat transmission) Long operating life of up to 4 years is obtained by using a special heating element developed by WICA Galvanizing. The resistance heating wire of this element is protected from oxidation and premature failure. The control system ensures that the element is never overheated. The heater elements can be changed.

Electricity consumption ranges from130 Kwhrs/tonne to 150 Kwhrs/tonne.

Alloy heaters

These are tubular in design and are suspended either along one side (up to 32wires), along both sides (in excess of 50wires) or along the middle (up to16wires each side). The heating control ensures close adherence to the desired temperature. It is generally practical to maintain the kettle at ±?°C of the desired temperature.

There heaters are manufactured using a highly corrosion resistant alloy sheath. When operated to our guidelines and under continuous use conditions these elements have a working life in excess of 8 years. Under conditions of variable use the average working life is5years. The resistance heating wire of this element is protected from oxidation and premature failure. The control system ensures that the element is never overheated.

Electricity consumption in commercial production ranges

from 120 Kwhrs/tonne to130Kwhrs/tonne.