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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EXAMPLE II A cokeless cupola operating with a clean charge and with what were mistakenly thought to be correct proportions in the vokeless including cokelfss Kg of dollastone furjace charge was fufnace to exhibit very rapid consumption of the spheres, with the consequence that the bed almost vanished by the end of an eight-hour shift, resulting in insufficient superheating and low metal temperature.

Besides suspended particulate matter, there are also carbon monoxide, carbon dioxide and sulphur emissions, none of which are good for the environment. Another way of deliberately increasing the volume of slag in the furnace is to re-cycle the slag.

This also ensures easy adaptation of the melting rate to the given requirements. There is no coke -related addition of sulfur. This is the purpose of the addition of limestone to the charge in the furnace; the limestone acts as a flux to absorb all these unwanted materials and form a slag which can be easily removed from the furnace and handled outside.

A method according to claim 16 wherein the silica comprises broken bottles, jars, gravel. This causes the iron to melt and being drained downwards.

Search Expert Search Quick Search. A method according to claim 11 wherein silica is added to the charge as a fluxing agent. Fuel cost may vary from region to region, and also due to variation in design, furnace capacity and duration of melt campaign. Each burner has its own gas, air and oxygen valves for precise regulation of burner performance.

The fupola had a similar composition to what had been used previously, i. In addition, the diagram shows cupolw the furnace temperature in the combustion zone increases, while the throat gas temperature in a greater height above the nozzles remains the same. In a unit melter frunace high tapping temperatures will be required. There is no ash to ucpola, so one of the main reasons for adding a flux has been eliminated. In addition most cupola furnaces are lined with a refractory material and as this gradually wears away this material must also be absorbed into the slag.

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Slagging is considerably reduced compared to copulas using coke. If insisted by the authority, a simple low cost wet cap may be installed to further reduce the emission level. 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.

As with other cupolas, steel scrap, scrap iron, return scrap, pig iron and slag forming agents can be used as charging materials. There is an increasing worldwide awareness of the impact that many processes can have on the environment. Schmelztechnik, Metallurgie, Schmelzbehandlung, 2nd edition,expert-Verlag. Wesman Group of Companies, Kolkata.

This example shows, amongst other things, the importance of the slag cupolx sufficient volume to flow during tapping, especially during continuous tapping.

Cokeless Cupola

The oxidation losses are lower than in a coke-fired furnaces so again, from this aspect, less flux is required. During continuous tapping the flow of slag from the furnace is continuous. Running the furnace at low slag volumes makes the slag thick and can cause blockage of the slagging and tapping box.

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

This illustrates the need to keep the slag sufficiently fluid to enable it to flow through the bed properly. Once a cupola has been converted to Cokeless Melting Furnace, the foundry would be in a position to produce ductile iron and some graded iron without cokelsss need for an electric furnace.

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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.

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 charge 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. Therefore, compared with a unit melter, the overall gas consumption also reduces. During continuous tapping the flow of slag from the furnace is continuous.

Using this method, the melting process already begins when starting to fill the furnace. The quality of the fuel cokeHC coke and the combustion process itself must be reproducible since all fluctuations have an impact on the melting process.

We have 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. We have to import coke from other countries. EXAMPLE II A cokeless cupola operating with a clean charge and with what were mistakenly thought to be correct proportions in the charge including 12 Kg of dollastone per charge was furnafe to exhibit very rapid consumption of the spheres, with the consequence that the bed almost vanished by the end of an eight-hour shift, resulting in insufficient superheating and low metal temperature.

Difficulties arose through bridging of the metal, and the slag was very sticky.