The document discusses four common types of kettle failures in galvanizing baths: 1) Burner leaks, caused by localized temperature increases from malfunctioning burners. 2) Flow leaks, caused by stagnating or turbulent heat at corners or sharp angles. 3) Dross leaks, caused by continuous dross accumulation lowering in the kettle. 4) Weird leaks near the bottom, possibly due to micro-cracks in old kettles. Most leaks are related to increases in local iron solubility from poor heat management.

1. Significant case histories of kettle failures: making sense of a complex phenomenon.

2. WHAT IS THE CAUSE OF A KETTLE FAILURE?

3. Is there a common factor to all extreme corrosion phenomena?

5. CASE 1: THE « BURNER LEAK » Found at a location directly influenced by flame. Commonly associated with malfunctioning burners. Can be controlled with regular burners checks and furnace maintenance.

14. CASE 2: THE « FLOW LEAK » Found at a location where heat is either stagnating or being increased by turbolence. Commonly associated with corners or sharp angles. Can be prevented by optimized design, is somehow inevitable.

19. CASE 3: THE « DROSS LEAK » Found at a location where a continuous dross accumulation has been present. Commonly associated with lower regions of the kettle, but can be close to top with crust accumulations. Can be easily avoided with good drossingleaning practices.

24. CASE 4: THE « WEIRD LEAK » Only to be found very close to kettle bottom, especially in old kettles. Usually not resulting in significant spill or leak, it is commonly believed to be caused by micro-cracks in the dross area.

26. APPENDIX: « MECHANICAL LEAKS » Found at a location where the kettle is physically broken by either tension or unsuitable welding. Commonly associated with uncontrolled overheating, bad packing or wrong welding materials. Can be prevented by materials selection and careful planning on heating stages.

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