COKELESS CUPOLA FURNACE PDF

Autotherm Equipments Corporation is well known manufacturer,exporter and supplier of Cokeless Cupola Furnaces at market leading price from Coimbatore,, . 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. The development of the cokeless cupola began in the United Kingdom at the foundry of Hayes Shell Cast Limited in the mid s. A pilot furnace was built.

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For ockeless foundries where expansion is being considered, the capital investment of installing a gas or oil fired Cokeless Melting Furnace could well be considerably less than adding additional electric furnaces. Pig iron Foundry pig iron Furnace clogging.

The cold-blast cupola furnace has a high specific coke consumption since a large part of the energy is discharged together with the exhaust gas in the form of carbon monoxide. Some examples will now be described to illustrate what can happen when a cokeless cupola is not run in accordance with the invention. Similar percentage of sponge iron may also durnace used in Cokeless Melting Furnace, provided fhrnace arrangements to charge the same are made.

This normally results in excessive consumption of the heat-exchange bodies. Therefore, this design can be used to produce iron with a low C-content, which is particularly interesting for foundries when it comes to the production of malleable cast iron.

However if lower temperatures are sufficient then the bed height can be reduced which will reduce the sphere consumption. It acts as a source of fufnace In the bed it superheats the iron as it trickles over the coke It acts as a source of carbon In the Cokeless Melting Furnace these functions are provided by three different means: This illustrates the need to keep the slag sufficiently fluid to enable it to flow through the bed properly.

To achieve tapping temperatures of around to deg C a bed height of around cokelezs would be required. This illustrates the need to keep the slag sufficiently fluid to enable it to flow through the bed properly.

The lower slag volume that results in the operation of the cokeless cupola is not a problem in intermittent tapping and is certainly an advantage for slag disposal. Only the simplest form of fume control is necessary and a simple wet cokeeless will enable the cupola to meet all known environmental standards.

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If high temperature metal is required from a coke cupola the coke consumption is increased cuppola. An electric furnace is not a very efficient melting unit but once the metal is liquid the superheating of the iron is very efficient.

In a unit melter fairly high tapping temperatures will be required. If insisted by the authority, a simple low cost wet cap may be installed to further reduce the emission level. Also, considering the shortage of power in India, it may be noted that when duplexed with Induction Furnace for production of Ductile Iron, the power requirement is reduced substantially.

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A method according to claim 1 wherein the furnace has a furnace lining which has a high alumina content. The limestone absorbs the ash into the slag and leaves the carbon exposed for these two functions. Running the furnace at low slag volumes makes the slag thick and can cause blockage of the slagging and tapping box. High draw speed plate blank continuous casting low carbon steel crystallizer protective slag.

We have discovered that the question of slag control is of surprising importance. With the unit melter operating at deg C, natural gas would be consumed at around 85 cu m per tonne with a typical sphere consumption of around 2. Anyway in a coke-fired cupola the tapping temperature is higher, which means that if the slag composition is not quite right the extra temperature will still enable the slag to be removed quite easily.

This avoids handling difficulties. Fuel cost may vary from region to region, and also due to variation in design, furnace capacity and duration of melt campaign. With these assumptions he can then calculate what changes must be made to the flux addition in order to obtain a fluid slag at the required tapping temperatures, yet, importantly, with minimum adverse effect on the spheres. If insufficient fluxing agents are added, the result is a slag which is viscous rather than fluid, and it does not flow easily through the spheres.

Thus with insufficient fluxing agents the furnace does not produce any metal at all. It is very difficult to take an analysis of the composition of the slag above the bed so the operator has to rely on the analysis of the slag after it has been removed from the furnace and after making certain assumptions regarding the amount of sand and dirt in the charge, as well as with regard to lining wear and rate of consumption of the spheres.

Difficulties arose through bridging of the metal, and the slag was very sticky. The principle of cupoka design is highlighted in the diagramatic drawing below.

US5294243A – Method of operating cokeless cupola – Google Patents

United States Patent Long-term furnace In line with the current state of the art, a long-term furnace can be designed with or without a lining. Picture shows metal being converted directly to ductile iron without desulphurisation. Anyway in a coke-fired cupola the tapping temperature is higher, which means that if the slag composition is not quite right the extra temperature will still enable the slag to be removed quite easily.

If more limestone were to be added in a cokeless cupola to maintain fluidity it would increase greatly the rate of consumption of the spheres, increasing the overall running costs as well as shortening the length of melting run that is possible. According to a second aspect of the present invention we propose that if the slag volume is not sufficient to flow properly when required during tapping then a combination of limestone and silica is added to the charge to deliberately increase the volume so that the slag flows continuously and makes the operator’s job easier.

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One major metallurgical advantage of this furnace type is the low sulfur content in the molten base iron which can be approx.

The bridging was found to have been due to the sticky slag being thrown back up the shaft and coating the charge. Automatic combustion control and indication of condition of all important services can be provided, as shown below. Instead it tends to be held above them and it then builds up in a layer above the spheres.

The liningless furnace does not have any refractory lining in any part of the shaft as is suggested by the term liningless; however, underneath the nozzles it is equipped with the same permanent lining as the long-term furnaces with lining. Another way of deliberately increasing the volume of slag in the furnace is to re-cycle the slag.

Cokeless Cupola Furnaces Manufacturer,Cokeless Cupola Furnaces Exporter,Supplier in Coimbatore

Wesman Group of Companies, Kolkata. The conventional operation of a cokeless cupola furnace has a requirement for a low volume of slag to be produced, because of the fact that there is no ash from coke to remove from the charge, and the fact that flux added to the cokelses to form slag eats away at the furnace lining, and at the bed of refractory spheres. A method according to claim 11 wherein sufficient flux materials are added to the melt to keep the viscosity of the slag below a critical value at which point the slag tends to be held above the heat-exchange bodies and has difficulty in flowing through the bed.

It has been shown in many instances that much cheaper metal will be obtained from the cokeless cupola compared with other forms of melting. In the siphon, slag and iron are separated Fig.

The most important aspect which fkrnace the invention is the use of refractory spheres in the cokeless cupola, as described in our British Patent Specification No. The flux additions must also melt above the bed and these additions are likewise superheated in passing down over the spheres.

There will still be some dust emissions from the charge but these can be readily removed if required.