The centerpiece of the Zinc Elephant³ is a three-arm handling system which automatically performs all handling operations from filling through to emptying of the baskets. It picks up the baskets and frames, dips them into the zinc bath, centrifuges them and takes them to the water bath for quenching. All operations from filling to emptying of the baskets are performed without manual intervention.

The process control system sets the process parameters – for example, the dipping time – with utmost precision. Thus the Elephant ensures a highly homogeneous coating layer. As the parts are handled very gently during galvanizing, handling damage is minimized. Therefore threaded bolts and similar parts do not require rethreading. This avoids the time-consuming effort and considerable costs of reworking.

As the parts can be pre-treated without the use of acids, Zink KÖRNER avoids hydrogen embrittlement and the resulting brittle fracture of the steel. This is a highly valuable feature for fastening elements used in offshore wind power plants, as they have to comply with extremely exacting anti-corrosion specifications.

The regenerative burner system reduces energy consumption by up to 20 percent versus other plants.

As the burners never operate under excess-air conditions, the amount of arising zinc ash can be cut by up to 70 percentage. Thus Zink KÖRNER markedly reduces material use and the effort for zinc ash removal.

Moreover, the galvanized parts are free of contamination, as the surface of the zinc bath is automatically skimmed before a basket is immersed and after boiling up.

The integrated process control system captures all plant states and stores the data relative to each individual basket. Each batch is completely traceable, meaning a high degree of security for the operator.

Hot dip galvanizing furnaces with ceramic pan and surface heating. A significant advantage of this type of furnace in comparison with the steel kettle furnace lies with the flexibility of the zinc bath temperature, which can be increased to about 600° C.

Additionally, a ceramic pan ensures an almost unlimited service life without interruption. This long service life is achieved through the selection of the most suitable customised cinder blocks. These are bricked so that long-term damage caused to the pan by the in-diffusing zinc can be prevented by using a system of cooling air ducts.

The heat energy is supplied directly to the zinc bath by the surface of the bath. With this in mind, a heating lid is fitted and includes the heating device and the exhaust gas stub.

For the purposes of isolation and optimal heat transfer, the vault of this lid is made of ceramic refractory material.