Cutting Solid Zinc - Help

[Bigblue73]

Cutting solid zinc. A local galvanizer here in Mid-Missouri had a kettle failure two weeks ago and dispersed about 30,000 pounds of molten zinc in the flame / air cavity. The material has since cooled and they have hired us to remove the blown out kettle. When asked to remove the now solidified zinc, we must have looked like we had a deer in the headlights expression on our faces. Out original thought is to arc gouges blocks of the material away and hoist it out of the pit. I am leaving out the safety items that are required. Is there a better way to cut solid zinc? Any help is appreciated.

[68sixspeed]

Crazy thought, might not be practicle on the large scale but doesn't zinc desolve in acid? I can't remember if it was hydrolcloric or what but I remember disolving the zinc center out of a penny and leaving the copper shell in chemstry. Could you use that to help loosen the zinc off the kettle. (pilot holes, etc?) Not sure on fumes though!

[Mathius]

when you say arc gouging, are you talking carbon arc removal?

How big a chunk are we talking here? 30,000lbs doesn't give me a good idea of the physical size.

Mathius

[toxicz28]

Gouge it, or use a demo saw if it's thin enough. But don't forget your safety equipment.

[Bigblue73]

The "void" is 12 feet long x 8 1/2" feet wide and by the look of the initial inspection the zinc is between 3 and 5 feet thick. It's a real mess. In doing some more research I've come across an Oxy-lance for the removal. The problem is that it is a strict demolition tool. It burns at 7500 degrees and blows through everything.

[toxicz28]

The "void" is 12 feet long x 8 1/2" feet wide and by the look of the initial inspection the zinc is between 3 and 5 feet thick. It's a real mess. In doing some more research I've come across an Oxy-lance for the removal. The problem is that it is a strict demolition tool. It burns at 7500 degrees and blows through everything.

That's alot of zinc!!! I was going to suggest a lance. I'm guessing the vessel is cast iron. If you've used a lance before, and have a delicate touch, it is possible to get the zinc down with one. You might scar up the vessel, but it won't blow "right" through it. If that's the route you take, I highly recommend an oxygen tanker trailer. Good luck.

[shep]

Is this in Glasgow? They are the only local ones I know of.

[Bigblue73]

Hey Shep - It's AB Chance in Centralia. They only do thier product, nothing from the outside like Monnings.

Toxic - I have never used a lance before. I'm the safety manager for my company so I'm very apprehensive to use this type of cutting tool. The lance is 10 foot long and is about 1 inch in diameter......get thi...it's last about 4 1/2 minutes. A tanker would be in order for this job. My real concern isn't the kettle itself, it's going to pulled and a replacement unit installed. The burner cavity is a ton of work that if I tear it up all schedules will be off. Someone came up with an idea to chip the material, hoping it would crack into chunks. All I see here is a huge mess.

[Damon777]

Hey Shep - It's AB Chance in Centralia. They only do thier product, nothing from the outside like Monnings.

Toxic - I have never used a lance before. I'm the safety manager for my company so I'm very apprehensive to use this type of cutting tool. The lance is 10 foot long and is about 1 inch in diameter......get thi...it's last about 4 1/2 minutes. A tanker would be in order for this job. My real concern isn't the kettle itself, it's going to pulled and a replacement unit installed. The burner cavity is a ton of work that if I tear it up all schedules will be off. Someone came up with an idea to chip the material, hoping it would crack into chunks. All I see here is a huge mess.

We have used these big lances in the past to burn through Silica refractories, iron slag, etc. (Iron foundry applications). I can tell you that you need an experienced hand if you need to salvage the vessel that the zinc is coming out of as it doesn't take long to rip through stuff you don't want to. FWIW, I've never seen one last 4 1/2 minutes. More like 2 minutes max.

We quit using them a couple of years ago based on safety concerns. If you have nobody with experience with them, I would strongly reccomend using any other method.

If you had a big iron mess on your hands, I would be able to help. I'm not familiar with many nonferrous metals, but I have a lot of contacts that are. I'll make some calls in the morning and see what I can come up with.

[68sixspeed]

Since the kettle is scrap, any chance you could get a cable saw in there? Or would that cut the burner? At least if you could saw the end of the kettle off you could work at the zinc from the end. Still doesn't sound like fun! Maybe get Mike Roe from Dirty Job's to come help.

[toxicz28]

I have to say, that's a big effin' lance rod! Most of the ones I've used are 3/8" by 20". Very easy to work with, but blind holes suck and they only lasted about 45-60 seconds. If you go with the lance, keep the cut about 1 1/2- 2" away from the cavity wall, and then chip and peel down the wall to remove the rest. Good luck!