The cupola furnace the many advantages cupola furnace has over any other kind of furnace for foundry work. The operation varies only in how the furnace is charged. Smelting in cupola furnace for recarburization of direct. Later, small blast furnaces were used to melt cast iron and scrap iron. The height of the cupola furnace may range from 20 35 feet. The cupola is a shaft type furnace whose height is three to five times its diameter. It is lined from inside with a refractory material. Cupola furnace, in steelmaking, a vertical cylindrical furnace used for melting iron either for casting or for charging in other furnaces. Cupola furnaces are highly efficient melt systems for continuous casting of gray iron and other metals. Construction of cupola furnace the cupola furnace consists of a cylindrical steel shell lined with a refractory material like firebrick and clay. Pdf herein the synthesis of ironcarbon saturated alloys foundries melting in cupola furnaces from direct reduction iron is described. The cupolette a basic guide to construction, installation.
Italy showed that these cupola furnaces could be used to obtain a wide range of grades of grey cast iron, including highcarbon cast iron 3. Cupola vs electric a battle for melting efficiency. Introduction to furnace thermodynamics kevin dartt. Alternating layers of metal and ferrous alloys, coke, and limestone are fed into the furnace from the top. The cupolas is one of the only methods of melting which is continuous in its operation. The life of the lining depends on the combination of four good factors. Some smaller cupolas may be ignited with wood to start the coke burning. The cupola is the major type of furnace used in the iron foundry industry. Unit ii melting furnaces before pouring into the mould, the metal to be casted has to be in the molten or liquid state. The extent of the losses depends on the furnace design, the fuel used, and the method of imparting heat to the metals. An operating cupola was quenched to obtain a picture of the internal structure.
The cupola is a refractory lined shaft furnace and the basic fuel is coke. Chemical combine with oxygen to provide the following white simultaneously minimizing the introduction of sulfur and slag components which adversely affect. Jamming of cupola furnace is a very common problem for which sufficient care should be taken to prevent it. So, many a times you have investment cost is less and operating cost is more whereas, in. Arc furnace high frequency induction furnace converter 3. Technical developments including application of computer models to optimize blast furnace operations. The main advantages of the cupola furnace are lower energy costs than those of competing furnaces electric and. Furnaces can also be classified according to the molten metal 1. Business metals, metalworking and machinery foundries iron industry production management steel industry. To begin a production run, called a cupola campaign, the furnace is filled with layers of coke and ignited with torches. Pdf experimental control of a cupola furnace researchgate. It melts iron with less fuel and more cheaply than any other any great damage heating and cooling. The cupola is a furnace used for melting steel scrap, cast iron scrap, and ferroalloys to produce cast iron. It is typically a cylindrical steel shell with a refractorylined or watercooled.
Home tags cupola furnace advantages and disadvantages. The cupolas is method of melting which is continuous in its operation, which make this furnace so important for iron industry. In duplexing melting operation two furnaces are used, and triplexing operations, three furnaces are employed 4 jamming of cupola furnace jamming of cupola furnace is a very common problem for which sufficient care should be taken to prevent it. The charge introduced in the cupola consists of pig iron, scrap, casting rejection, coke, and flux. The melting process is not only responsible for the energy consumption and. Ecomelt cokeless melting furnace is a vertical shaft melting furnace and was as a melting unit for cast iron without use of coke as in a conventional cupola. Furnace, cupola a shaft furnace for smelting iron in casting production. High performance castable refractories for cupola applications. Exhibit 1 compares the efficiency and metal loss for different types of furnaces. This furnace is generally supported on four cast iron lags mounted on a concrete base.
Minimizing the downtime for these repairs is essential to keeping the foundry in operation. A schematic diagram of a cupola is shown in figure. Cupola furnace constructed in the form of a hollow cylindrical vertical steel shell and it is lined from inside with a refractory material. Experimental control of a cupola furnace conference paper pdf available in proceedings of the american control conference 6.
The 1d, firstengineeringprinciples model includes mass. Intelligent control of cupola melting foundry gate. A blast furnace performs basic melting of iron ore operation to get pig iron, cupola furnace is used for. Effect of coke properties on cupola furnace operation and. In this region silicon from fesi continues to combine with steel drops as indicted by reaction 6. In duplexing melting operation two furnaces are used, and triplexing operations, three furnaces are employed. The bottom of the furnace is closed by two cast iron doors hinged to the bed plate of the furnace. Furnaces can also be classified according to the molten metal. The cupola furnace is open at the both its top and bottom.
It can be used as a batch melter single tap and is not solely relegated to melting cast iron. Slag, which is basic, tends to combine with acid oxides of some elements silica. It is typically a cylindrical steel shell with a refractorylined or watercooled inner wall. Advantages of melting cast iron in gas cupola furnaces. Insertec manufactures refractory masses and precast shapes for cupola furnaces for iron foundry. This is article about cupola furnace, which is used to melt pig iron, cast iron, bronze etc. Cupola furnace the cupola showing the general inputs and outputs. The main objective of the present work is the utilization of waste material rice husk briquette of low c. Construction and working of cupola furnace it is the constructed in the form of a hollow cylindrical vertical steel shell. The development of the cokeless cupola began in the united kingdom at the foundry of hayes shell cast limited in the mid s. Anthracite coal or carbon briquettes may also be used.
The upper portion of the cupola is termed the stack. To the foundry using a cupola for melting, the furnace is the heart of the foundry providing molten iron to the rest of the operation. Cupola furnace from wikipedia, the free encyclopedia a cupola or cupola furnace is a melting device used in foundries that can be used to melt cast iron, niresist iron and some bronzes. Although there are different types of cupola but this manual focuses on single blast and. Iron melting cupola furnaces for the small foundry. Cupola furnace computer process model technical report. During the operation, the cupola is kept filled to charging door. While industrial cupolas are constructed with the same basic design as those in common use since the industrial revolution, todays cupola furnaces are digitally controlled and highly automated. For this reason the correct operation should be hot and basic, with tall coke. A mathematical model for a mineral melting cupola furnace.
Cupola furnace article about cupola furnace by the free. A mathematical model of a mineral melting cupola furnace for stone wool production has been developed for improving cupola operation. A cupola furnace is a melting device used in foundries that can be used to melt cast iron, ni resist iron and some bronzes cupola furnace is employed for m slideshare uses cookies to improve functionality and performance, and to provide you with relevant advertising. Home dam operation based on water level dam operation based on water level3. Best operating practices bureau of energy efficiency. Large cupolas may produce up to 100 tonshour ofhot iron. Steel can be also prepared in cupola by employing duplexing and triplexing operations. It is generally supported on four cast iron lags mounted on a concrete base. Autotherm equipments corporation is well known manufacturer,exporter and supplier of cokeless cupola furnaces at market leading price from coimbatore. The cupola furnace has several unique characteristics which are responsible for its widespread use as a melting unit for cast iron.
Large furnace, and can be run intermittently without from expansion and contraction or small quantities of iron in may be melted in the same furnace. Cupola furnace is the cheapest means for converting pig iron or scrap metal into gray cast iron. Scope covers recommended sizes of divided blast cupolas for use in foundries. It is one of the oldest methods of producing cast iron, and it remains the dominate method because of its simplicity and low fuel cost. When the coke is ignited, air is introduced to the coke bed through ports in the sides called tuyeres. Gray cast iron cupola air furnace rotary furnace electric arc furnace 2. Replacement of split coke charge in cupola operation. Furnace is used for carrying out not only the basic ore refining process but mainly utilized to melt the metal also. The cupola is primarily a shafttype furnace used to remelt pig iron and ferrous mixes in direct contact with the fuel in a continuous operation.
So, they will combine with air and then they will be heated, and then they will be. Furnace operations the three most common furnaces used in the iron foundry industry are cupolas, electric arc, and electric induction furnaces. Pdf we present some final results from a research project focused on introducing automatic control to the operation of. These furnaces became the prototype of the modern cupola furnace. The use of high quality refractory linings ensures reliable operation of the cupola furnaces. Partial replacement of coke in cupola operation, transaction of the american foundrymen society, proceedings of the eighty.
The whole furnace is supported above floor level on pillars. Cupola furnace spinning machine exhaust air cleaning trim line. Until the second half of the 18th century metal for castiron production was obtained directly from ore in blast furnaces. Pdf smelting in cupola furnace for recarburization of direct. Between the cupola furnace and induction mixer the flow of the cast iron is treated by the cac2 and cao in the small intermediate ladle stirred by the argon gas. Fireclay whiish in color should be used for joining the bricks. The combustion products leaving the charge pass through the stack to the atmosphere. Smelting in cupola furnace for recarburization of direct reduction iron dri 3. The prime criterion for the commercial acceptance of new advanced melting technologies is that they must not be capital intensive for installation. The cupola furnace works on the principle where we generate heat from burning coke and when the temperature of the furnace is above the melting point of the metal then the metal is melt.
1013 1098 1327 1317 1651 781 710 195 278 1455 1152 150 71 1337 902 600 1664 227 941 155 1334 773 1546 986 1185 1496 638 1068 1328 1465 891 158 722 504 1273 220 1437