Zinc kettle replacement in Feuchtwangen: How the largest kettle in the WIEGEL Group was replaced

Feuchtwangen – Replacing a zinc kettle is one of the most technically demanding measures in a galvanizing plant during ongoing operations. In Feuchtwangen, colleagues from the Technical Department at the WIEGEL headquarters in Nuremberg supported the local team in replacing the largest kettle in the group. In a 90-second video, Peter Zorn from the Technical Department explains the key steps and background information.

Dimensions and preparation

The kettle in Feuchtwangen is 17 meters long and holds nearly 700 tonnes of zinc. On the day of pumping out, the molten zinc was distributed into around 250 zinc ingot moulds. These steps require precise planning, as the zinc must be handled and distributed appropriately under the prevailing temperatures and process conditions.

A crucial aspect is preheating the pipeline: for pumping to work, the line must be brought to a sufficient temperature. Otherwise, the zinc at 450°C could have solidified in a cold pipeline at the start of pumping and prevented the process. Preheating is therefore an essential prerequisite for a controlled procedure.

Lifting with special cranes

The actual replacement is carried out using two mobile cranes from Biedenbach with lifting capacities of 300 tonnes and 150 tonnes. These specialist cranes were used to lift the 67-tonne kettle into the plant. Coordinating the crane lift, insertion route and plant conditions was decisive to position the kettle safely and precisely. According to the scale, the decommissioned kettle registered over 100 tonnes because residual amounts of zinc and hard zinc remained in the kettle after operation.

Short report and further insights

The video provides a concise summary of the process and shows what matters in a kettle replacement of this scale: preparation, temperature control, suitable lifting technology and well-coordinated teamwork.