1.13. MELTING FURNACES Various types of melting furnace are used in the foundry shop. The type of furnace used depends upon the type of metal and the quantity of metal to be melted. The metal melting furnaces used in foundries are: = > Blast furnace => For smelting iron to produce pig iron Cupola furnace = For cast iron Open hearth furnace => For steel Crucible furnace => For non-ferrous metal a) Pit type furnace b) Coke fired stationary furnace c) Oil fired tilting furnace Pot furnace6. Electric furnace a) Direct arc furnace b) Indirect arc furnace ¢) Induction furnace 4.13.1. Blast Fumace A blast furnace, shown in Figure 1.62, is a type of furnace used for smelting metal ore. usually iron ore. The combustion material and ore are supplied from the top while air flow is supplied from the bottom of the chamber so that the chemical reaction takes place not only at the surface throughout the ore. This type of furnace is typically used for smelting iron to produce pig iron which is the raw material for wrought and cast iron. Core, iron, ore and limestone Blast furnace gas Alternate layers of coke and iron ore Refractory lining Hot air Figure 1.62 Blast Furnace—~ Blast furnace is named so because very high temperature is developed inside the furnace by forcing a blast of heated air. Its height is about 30 m and interior diameter is of 8 m. Working: The furnace is built in the form of a tall, chimney-like structure lined with refractory bricks. Coke, limestone and iron ore (iron oxide) are poured-in at the top. Air is blown-in through tuyeres near the base. This “blast” allows the combustion of fuel. It reduces the oxide in the metal which is being heavier sinks into the bottom of the furnace. The nature of reaction takes place inside the furnace given by Fe.03 + 3CO => 2Fe + 3CO2 More precisely, the compressed air blown into the furnace reacts with the carbon in the fuel to produce carbon monoxide which then mixes with the iron oxide, reacting chemically to produce iron and carbon dioxide which leaks out of the furnace at the top. The temperature in the furnace is typically about 1500°C which is also enough to decompose limestone (calcium carbonate) into calcium oxide and additional carbon dioxide: CaCO; => CaO + COr The calcium oxide reacts with various acidic impurities in the iron (notably silica) forming a slag containing calcium silicate, CaSiO3 which floats on the iron. The slag floating over the molten metal is removed through the slag notch. The heavier pig iron is taken out using a tap hole at the bottom of the furnace. The pig iron produced by the blast furnace is not very useful due to its high carbon content (around 4 -5 %) which makes it very brittle. It is used to make cast iron goods often being remelted in a foundry cupola. The blast furnace remains an important part of modem | production. Modern furnaces include Cowper stoves to pre-heat the blast air to high temperature in order to avoid cooling the mix and having re-heat. They use fairly complex | systems to extract the heat from the hot carbon dioxide when it escapes from the top of the | furnace, further improving efficiency. The largest blast furnaces produce around 60.000 tonnes of the iron per week. 1.13.2. Cupola Furnace This type of furnace is used for melting cast iron. Construction: It is a vertical and cylindrical shell made of 10 mm thick steel plate. It is lined with refractory bricks inside. Two bottom doors close the bottom of the cupola. A sand bed is laidSs over the bottom doors sloping towards the tap hole, Molten metal stays over this bed. Th e legs are set at the bottom of the furnace using a concrete There is a tap hole for taking the molten metal. A plug made of clay closes the tap hole. The slag hole is Provided in the shell above the tap hole. The slag floating over the molten metal 1s removed through this slag hole. The opening, called tuyeres, are provided one meter above the bottom. Fuel is supplied through these tuyeres for making, complete combustion of fuel. There is a wind box and blower for the supply of air into the furnace. For charging the metal and fuel into the furnace a separate charging door is made. Spark arrester H H H Steel shell 4 y il H, Aj— Charging door a 4 Metal eee y y YJ Y Fees Preheating x Y : y zone A Yj “VAL Brick lining Bis 8. ---}-------- Yj V) : GY ne ° nl y Y Wind Box pee et 4 AL-Y Coke Air —> Tap hole Slag hole —>' Sand bed Bottom door Figure 1.63 Cupola furnacePreparation: nad rea a an previous melting are cleaned. Broken bricks are repaired o hole ie ona ry. " ttom doors are closed. A sand bed with sloping towards tay Pp to a height of 200 mm. A tap hole is formed and lined with clay. Then 4 slag hole is prepared. Finally, the cupola is dried thoroughly. Firing: Oil waste and wooden pieces are placed at the bottom and the fire is started. Now, the sufficient amount of air is supplied when the wood starts burning. The coke is charged several portions. Now, the coke burns. Again and again more coke is added up to the tuyere evel. The blast is turned off. Coke is again added up to the level of bed charge ‘Then, the coke is allowed to bum for half an hour. Finally, the charging is done through the changing door. Charging and melting: Pig iron and iron scrap are charged into the furnace through the charging door. Then coke is charged alternatively. Limestone is added to the charge to remove impurities and also to ensure tiorough mixing of molten metal, The ratio of pig iron to limestone and pig iron to coke are 25:1 and 10:1 respectively. The cupola is fully charged. Then, the iron is soaked for cone hour. After that, the blast is turned on. The molten metal will begin to collect at the sand bed. After melting enough quantity of molten metal, clay plug is removed and collected in ladles. Then the molten metal can directly be poured into moulds. The floating slag on the top layer of the molten metal is tapped out through the slag hole. Again the furnace should be charged to the full level for repeating the same procedure. At the end, the cupola is shut off by stopping the air blast, Then, the remaining moltet metal is removed, the bottom doors are opened, the wastes are dropped down and they are quenched by water. Application: Cupola is used to melt cast iron. Advantages: 1. Initial cost is comparatively less than other type of furnaces. 2. It is simple in design. 3. It reauires less floor area-ar Casting Processes 4. Operation and maintenance are simple 5. Mean be operated continuoys! y tox a