LECTURE 10
Foundry Furnaces
Cupola
1. Vertical cylindrical furnace meant for melting pig iron.
2. Used only for cast irons. Although other furnaces are also
used, the largest tonnage of cast iron is melted in cupolas.
3. The "charge," consisting of iron, coke, flux, and alloying
elements (if used), is loaded through a charging door located
less than halfway up height of cupola
Cupola furnace
Cupola for melting
pig iron
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Working of a Cupola Furnace
CUPOLA FURNACE
• The construction of a conventional cupola consists of a
vertical steel shell (0.5 to 4m in diameter) which is lined
with a refractory brick.
• The charge is introduced into the furnace body by means of an
opening approximately half way up the vertical shaft.
• The charge consists of alternate layers of the metal to be
melted, coke fuel and limestone flux.
• The fuel is burnt in air which is introduced through tuyeres
positioned above the hearth. The hot gases generated in the
lower part of the shaft ascend and preheat the descending
charge.
Various Zones of Cupola Furnace
1) Well/Hearth/Crucible
Zone
2) Combustion Zone/
Oxidizing Zone
3) Reducing Zone/
Protective Zone
4) Melting Zone
5) Preheating Zone
6) Stack
Chemical Reactions
1. Well – The molten metal gets collected here before tapping out
2. Combustion Zone – Height of this zone is 15 – 30 cm, and temp varies from
1540 to 1870 Deg C
C + O2 → CO2 + Heat
Si + O2 → SiO2 + Heat
2Mn + O2 → 2MnO + Heat
3. Reducing Zone – Temp is around 1200 Deg C
CO2 + C (coke) → 2CO + Heat
4. Melting Zone –
3Fe + 2CO → Fe3C + CO2
5. Preheating Zone – Temp. is around 1000 Deg C
Blast Furnace (Smelting Process)
Capacity of Cupola
It is defined as the tonnes of molten metal obtained per hour of
the heat. It usually varies from 1 – 15 tonnes / hour
Metal: fuel ratio = iron : coke ratio
Numericals
1) A fan supplies 100 cu m of air per minute to a cupola. If
the air required to melt one ton of metal is 1000 cu m per
hour, calculate the capacity of cupola. Assume 10%
leakage in the pipe line.
Taking 10% leakage in the pipeline;
Air supplied by the fan in one minute = 100* 0.9 = 90 cu.m
Air supplied by the fan in one hour = 5400 cu. m
Air required to melt one ton of metal = 1000 cu. m per hour
Total tonnage of melt produced by 5400 cu.m of air supplied in one
hour
5400
= = 5.4 𝑡𝑜𝑛/ℎ𝑟 (capacity of cupola)
1000
2) A cupola 75 cm in diameter has a melt ratio of 10:1.
How much iron is melted per hour? How much coke is
consumed per hour? Assume a melting rate of 0.562
kg/hr/cm2
Advantages and limitations
Advantages of Cupola:
a) It is simple and economical to operate.
b) It is capable of accepting a wide range of materials without reducing melt
quality.
c) High melt rates and ease of operation
d) Less floor space requirements comparing with those furnaces with same
capacity.
Limitations:
1) Since molten iron and coke are in contact with each other, certain elements
like Si, Mn are lost and others like sulphur are picked up. This changes the final
composition of molten metal.
2) Close and precise temperature control is difficult to maintain
Other furnaces…
▪ Direct fuel fired furnaces
▪ Crucible furnaces
▪ Electric arc furnaces
▪ Induction furnaces
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Direct Fuel-Fired Furnaces
1. Small open-hearth furnace in which
charge is heated by natural gas fuel
burners located on side of furnace
2. Furnace roof assists heating action
by reflecting flame down against
charge
3. At bottom of hearth is a tap hole to
release molten metal
4. Generally used for nonferrous
metals such as copper-base alloys
and aluminum
Crucible Furnaces
1. Metal is melted without direct contact with burning fuel
mixture. Sometimes called indirect fuel-fired furnaces.
2. Container (crucible) is made of refractory material or
high-temperature steel alloy.
3. Used for nonferrous metals such as bronze, brass, and
alloys of zinc and aluminum
4. Three types used in foundries: (a) lift-out type, (b)
stationary, (c) tilting
Three Types of Crucible Furnaces
(a) Lift-out crucible, (b) stationary pot - molten metal must be ladled,
and (c) tilting-pot furnace
Electric-Arc Furnaces
1. Charge is melted
by heat from an
electric arc.
2. High power
consumption.
3. Electric-arc
furnaces can be
designed for high
melting capacity
4. Used primarily for
melting steel
Induction Furnaces
1. Uses alternating current passing through a coil to develop
magnetic field in metal.
2. Induced current causes rapid heating and melting
3. Electromagnetic force field also causes mixing action
4. Since metal does not contact heating elements,
environment can be closely controlled to produce molten
metals of high quality and purity
5. Common alloys: Steel, Cast Iron, and Aluminum
Induction Furnace
Advantages of Induction furnace
1) Low cost raw materials can be used
2) Better control of temperature and composition can be
achieved
3) Higher yield
4) Natural stirring and compact installation
5) Cleaner melting
Reverberatory Furnace
