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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In the conventional coke-fired cupola furnace the importance of slag control is recognised and the mechanism is fairly well understood.

The lower slag volume that results in cokelese operation of the cokeless cokdless is not a problem in intermittent tapping and is certainly an advantage for slag disposal. This normally results in excessive consumption of the heat-exchange bodies.

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.

USA – Method of operating cokeless cupola – Google Patents

A carbon injection unit, therefore, will be required which continually blows carbon into the cupola during melting. Broadly speaking, therefore, the invention is based on an appreciation of cupoa importance of slag control in the cupolq of a cokeless cupola furnace with the minimum of trouble, in particular without problems originating from a slag which is too viscous, yet at minimum cost, that is to say, low sphere consumption and low lining wear.

During continuous tapping the flow of slag from the furnace is continuous.

There is an increasing worldwide awareness of the impact that many processes can have on the environment. Simpler more manual systems are also manufactured. However, this has a slight negative impact on carburization. As there is no carbon pickup in the Cokeless Melting Furnace, this is added either by continual injection into the well of the Cokeless Melting Furnace or outside in an electric furnace.

This control may involve deliberately increasing the volume of slag by suitable additions in order to operate a continuously tapped furnace smoothly.

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Reducing the amount of undesirable ferrous – cpds in a cupola furnace during batch. Difficulties arose through bridging of the metal, and the slag was very sticky.

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.

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Best viewed in IE 7. 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.

However if lower temperatures are sufficient then the bed height can be reduced which will reduce the sphere consumption. An important feature of the cokeless cupola is that during operation there is no visible emission and the actual solids emitted are very low and dokeless only dependant on the cleanliness of the charge.

The Cupla level, as measured in actual installations, is less than one third the allowable limits. Immediately the slag flowed with good fluidity and the bridging problem disappeared. Foundries with coke cupola may be limited as to the amount of steel scrap they can use particularly if they are trying to obtain relatively high carbons. If the exhaust gas is extracted in the feed area extraction above throatfalse air is introduced at least during charging, rendering thermal recovery inefficient.

Fluorine-free environment-friendly type continuous casting protecting slag for the blast furnace slag containing titanium and the manufacturing process of the same. A method according to claim 2 wherein limestone, dollastone is added to the re-cycled slag as another component of the fluxing agents.

The lining may be consumable and may comprise a silica ganister, or for certain applications a lining with a high alumina content. Generally limestone or dollastone is used as the fluxing material, or sometimes a mixture of the two.

Particular benefits include a guaranteed reliable production process with only little spread in iron composition. The carbon content of the metal can be easily altered by changing the injection rate at the control panel.

It was patented by him in the year Even fuurnace the metallic charge is known to be of pure metal free from dirt and sand, it is still essential to add fluxing agents to form a slag, if only to absorb the products of lining wear and sphere consumption.

In a coke-fired cupola it is important that the carbon in the coke should be easily released from the coke so that it durnace act both as a fuel, generating the necessary heat, and as a source of carbon for the metal, primarily where the metal is iron or a ferrous alloy.

The investment costs are low compared to other units. During continuous tapping the flow of slag from the furnace is continuous. In pressurized siphon operation, iron and slag do not accumulate in the furnace but are immediately drained after dripping off. Slagging is considerably reduced compared to copulas using coke. Year of fee payment: The lining may be consumable and may comprise a silica ganister, or for certain applications a lining with a high alumina content.

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The rate of injection can be controlled. A method according to claim furnnace wherein the silica comprises broken bottles, jars, gravel. There is no coke -related addition of sulfur. As a cokelwss one of the existing 5 tonnes per hour cupolas was converted to a gas-fired cokeless system in November The principle of the design is highlighted in the diagramatic drawing below.

The most important aspect which highlights the invention is the use of refractory spheres in the cokeless cupola, as described in our British Patent Specification No.

Apparatus for melting scrap.

Here, the desired iron temperature is regulated electrically and the composition is adjusted by adding the appropriate alloy. However, with continuous tapping we have found that this low slag volume can cause operational problems as the slag does not flow continuously from the front tapping and slagging box.

The melting zone is closer to the nozzles than in cold-blast cupolas. 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. Even Light Oil may be used provided there is no Sulphur cokdless the oil.

In a coke-fired cupola it is important that the carbon in the coke should be easily released from the coke so that it can act both as a fuel, generating the necessary heat, and as a source of carbon for the metal, primarily where the metal is iron or a ferrous alloy. Dust removal can be accomplished by wet washer or dry means fabric filter ; today, fabric filters are considered state of the art.

As can be seen in Fig. We chpola discovered that slag control is essential to the correct operation of a cokeless cupola as opposed to being of minor importance as was previously felt. A method according to claim 11 wherein silica is added to the charge as a fluxing agent.