Group 10
CUPOLA FURNACE
Group members :
Bima Tegar Pribadi (02511740000012)
Hanif Shabri Baktidillah (02511840000052)
Darrel Muflih Arrahman (02511840000063)
Fernanda Fadhlurrahmanditio Dwi Putra (02511840000078)
OUTLINE
[Link] 3.
1.
FURNACE MECHANIS
INTRODUCTIO
APPLICATION M OF
N ABOUT
S ON CUPOLA
CUPOLA
CASTING FURNACE
FURNACE
FIELD
[Link]
4. WORKING
OF CUPOLA
PRINCIPLE OF
FURNACE ON
CUPOLA
RESEARCH 3
FURNACE
LAST YEARS
6. ADVANTAGES 5. DETAIL PARTS
7. NEWEST OF CUPOLA
AND
TECHNOLOGY AND FURNACE AND
DISADVANTAGE
RESEARCH ON THEIR
S OF CUPOLA
CUPOLA FURNACE FUNCTIONS
FURNACE 2
1. Introduction
Introduction about Cupola Furnace
The cupola furnace is a shaft furnace whose primary characteristic is its
height. Thermically it is a counter current heat exchanger. During
combustion, air enters through tuyeres and burns the coke inside,
releasing heat.
The melted metal drips through the coke bed and falls to the hearth,
draining out through the tap hole. The high level of thermal efficiency of
this type of furnace allows the melting of any material.
● Cupola furnace is similar to a small blast furnace. It is
cylindrical in shape and the cambers are arranged vertically.
● It is usually fabricated with mild steel (flat sheet plates) and
special clay or refractory bricks are used as inner lining
materials. It utilizes coke & limestone as the main source of
fuel and fluxing agent respectively.
● The furnace is mainly used, for the casting of grey
cast iron and for the casting of white or chilled cast
iron. Grey cast iron is produced by melting together
low quality foundry pig iron scrapped casting and
coke in a cupola.
SMALL BLAST CUPOLA
FURNACE FURNACE
5
02. Cupola Furnace
Application on
Casting Field
Cupola Furnace Application on
Casting Field
Cupola Furnace mainly used to convert pig iron to molten iron.
The copper base alloy is also manufactured by Cupola Furnace
03. Mechanism of
Cupola Furnace
4.
2. Smelting process occur in the cupola
Furthermore, the aglomerated ore is evenly furnace body chamber that are divided into
mixed with coke (as a reducing agent and stack zone, preheating zone, combustion
fuel), and a flux such as limestone. zone, and melting zone.
1. 3.. 5..
Then, the mix of ore, coke, The dispensing process of molten
Before smelting process, the ore
and flux is being fed to the metal and slag is happening
must be preparated first by
cupola furnace step by step through tap hole. Firstly pouring
aglomeration process such as
through Charging Door the slag through slag spout, and
sintering or pelletizing
next pouring the molten metal
(Aglomerated)
through tapping spout.
04. Working Principle
of Cupola Furnace
4.
2. Then the air blast is turned on and
The charge introduced in the cupola combustion occurs rapidly within the coke
consists of pig iron, scrap, casting rejection, bed. Within 5 to 10 minutes after the blast
coke, and flux. Coke is the fuel and is turned on the first molten cast iron
limestone are added as a flux to remove appears at the tap hole. Usually, the first
undesirable materials like ash and dirt. The iron which comes out will be too cold to
scrap consists of Steel and cast iron pour into sand molds. During the cupola
rejections. operation, molten metal may be tracked
every 10 minutes depending on the melting
rate and the capacity.
3.
1. The working of Cupola furnace is, Over the sand Bottom,
The Cupola furnace works on the Coke in charged extending up to a predetermined height. This
principle where we generate heat from serves as the coke bed within which the combustion takes
burning coke and when the temperature of place. Cupola operation is started by igniting the coke bed at
the furnace is above the melting point of its bottom. After the Coke bed is properly Ignited, alternate
the metal then the metal is melt.
charges of limestone, pig iron, and coke are charged until the
level of the charging Door.
6. 8.
The first layer of iron above the reducing zone
Then,hot gases consisting principally of
is the melting zone where the solid iron is
Nitrogen and carbon dioxide moved upward
converted into the molten state. A significant
from the combustion zone, where the
portion of the carbon is picked up by the metal
temperature is 1650 degree Celsius.
also takes place in this zone.
5. Exothermic Reaction 7. Endothermic
The portion of the cokeReaction
bed if the combustion zone is reducing zone.
All the oxygen in the air blast is consumed by It is a protective zone to prevent the oxidation of the metal charge
the combustion, Within the combustion zone. above and while dropping through it. As the hot carbon dioxide gas
The chemical reaction takes place which is, moves upward through the hot coke, some of it is reduced by the
C + O2 (from the air) → CO2 + Heat following reaction.
The temperature in this zone varies from 1550 3Fe + 2CO → Fe3C + CO2
to 1850 degree Celsius.
[Link]
Final
gas isStep
passed upward from the reducing and
melting zones into the preheating zone which includes
all layers of charge above the melting zone up to the
charging Door. Since the layer of the charge is
preheated by the outgoing gases which exist at the top
of the cylindrical shell. this temperature is this zone is
around 1090 degrees Celsius.
05. Detail Parts of
Cupola Furnace
Detail Parts of Cupola Furnace
1. Cylindrical Shell :It is the outermost part of the Cupola furnace. It is made up of steel sheet
and other parts of this furnace are present inside this shell.
2. Legs : At the bottom of the Cupon furnace legs are provided to support this furnace.
3. Cast Iron Door :This cast iron is present at the bottom of the furnace above the legs which is
closed by the support of the legs.
4. Sand Bed :Above the cast iron door sand bed is present. It is in taperred form so that the
melted iron can flow out easily from its top.
5. Air Pipes and Tuyers : The air pipe is provided to allow the air to reach inside the furnace.
Inside the furnace wind belt is present. The air entering from the air pipes reaches each part of
the wind belt and in the wind belt there are holes which are called tuyers. Air reaches the
furnace through this tuyers and will help in combustion.
6. Spark Arrester : It is present at the top of the furnace. When gases are released out of the
furnace, some burning particles are present in it which can harm the environment. So this cap or
spark arrester is used to capture the burning particles and allow the gas to pass to the
environment.
Detail Parts of Cupola Furnace
7. Charging Door : It is present near the top of the furnace. It is used to supply charge to the
furnace. The charges in this furnace are Pig Iron, Coke and Lime Stone. Coke is used for
combustion, pig iron is the material that is to be melt and lime stone is used as a flux.
8. Well: The part of the furnace from the send bed to lower part of tuyers is known as Well. It
is named as well as in this part molten iron is stored and then the molten iron comes out of the
tapping hole.
9. Tuyers Zone: The part of the furnace in which the wind belt and tuyers are present is
known as Tuyers Zone.
10. Combustion Zone: In this zone combustion takes place. The air coming from the tuyers
contains oxygen and this oxygen reacts with carbon to form carbon dioxide. It is also known
as oxidixing zone as carbon oxidizes in this zone to form carbon dioxide and liberate heat.
11. Reducing Zone: It is present above the combustion or oixdizing zone. It this zone carbon
reacts with carbon dioxide to form carbon monoxide.
Detail Parts of Cupola Furnace
12. Melting Zone: In this zone iron melts and this molten iron comes out of the tap
hole. The temperature of this zone is very high nearly 1600 degree Celcius.
13 Preheating Zone: In this zone the metal to be melted is preheated, in this zone
metal is heated to about 1090 degree celcius.
14 Stack Zone: Gases formed in the furnace after burning passes to the environment
through this zone. In this zone, spark arrester is present which prevent burning
particles to reach the environment.
06. Advantages and
Disadvantages
Advantages
The cupola furnace has several unique characteristics, which are
responsible for its widespread use as a melting unit for cast iron.
● The cupola is one of the only methods of melting which is
continuous in its operation
● The possibility of steady melting of a wide range of cast
irons with various carbon and low sulfur content, including
spheroidal graphite irons; better mechanical properties of
cast iron, lower sensitivity to changing wall thickness
● High melt rates
● Relatively low operating costs
● Ease of operation
● Simple in Construction.
● Wide range of material can be melted.
Disadvantages
● Sometimes it is very hard to control the
temperature in this furnace.
● Metal elements are converted to their oxide
which are not suitable for casting.
● Cupola furnaces burn coke with an air blast to
melt scrap steel, cast iron, and alloys into a
consistent grade of iron. The variations in charge
composition and blast effectiveness, among
other variables, make the grade of iron produced
less predictable.
07. Newest
Technology and
Research on Cupola
Furnace
Newest Technology and Research on
Cupola Furnace
HEAT LOAD ANALYSIS FOR OPTIMAL USE OF CUPOLA FURNACE IN IRON CASTINGS AND
STEEL MANUFACTURING (2019)
● Basically, the cupola furnace handles almost 90% of pig iron
produced from the blast furnace. Raw materials ordering than pig
iron for cupola operations are metal scraps, wrought iron, steel,
cast iron, and bronzes.
● It is a high point of emphasis that over the years a lot of innovative
techniques had been introduced geared towards optimal
throughput delivery of cupola furnace systems — cupola furnaces
designed with performance efficiencies in the range of 30% to
50%.
● This consideration is to ensure maximum heat conservation and
recovery for optimal throughput delivery. . This research is to
improve the thermal performance of the furnace which
inadvertently would significantly impact upon the furnace
throughput delivery, hence, enhance performance efficiencies of a
08. Application of
Cupola Furnace on
Research 3 Last Years
Melting in a Gas Cupola Furnace of Heterogeneous Refractory
Bed Charge by Cupola Furnace
● The data below show that making the refractory bed charge of refractories only (melting 24.3) did
not ensure stability of operation, and significantly impaired smelting characteristics. Carbon burn-
out was 42.8%
● In this melting, the charge mixture consisting of ● Melting with the use of refractory bed charge
100% recycled material was melted. The consisting of 100% electrode scrap, unlike
obtained cast iron contained 2% of carbon. The Si melting with the use of refractory bed charge
burn-out was insignificant due to the influence of consisting of 100% coke, was not stopped
temperature conditions. The manganese burn- prematurely, and the temperature of cast iron in
out amounted to 40.7%. Obviously, adding the melting 24.8 reached 1,400 °C, but the
oxides would also result in its reduction, and their consumption of electrode scrap was 5% of
absence eliminated the effect of temperature loaded metal.
conditions, and allowed restoring due to the
carbon dissolved in the metal. Consumption of
the refractory material in this case was quite
significant (3.5%).
● Meltings with the use of fire clay and coke ● As a result, The metallurgical parameters
mixture yielded good results. Melting 21.12 is of obtained in a gas cupola furnace with
special interest. The charge mixture consisted of heterogeneous refractory bed charge are much
100% scrap steel, and we obtained cast iron, or, higher than those obtained in conventional gas
more precisely, intermediate product, which cupola furnaces. When melting with the use of
contained 1.5% of C, 0.19% of Mn, and 0.61% of charge consisting of 100% scrap iron in a gas
Si. The content of carbon increased from 0.3 to cupola furnace, Fe burn-out is 1.47%, even
1.5%. Other meltings were made with the use of when the air heated up to 600 °C. That is
the charge that consisted of pig iron (up to 40%), almost three times higher than melting in a gas
and iron scrap (recycled) with the same chemical cupola with heterogeneous refractory bed
composition. It has been found that increasing charge.
the content of coke in refractory bed charge
resulted in decreasing temperature and reducing
burn-out. With the coke content as much as
20%, carbon content increases.
Cupola Furnace
Animation Video
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Summary
● Cupola furnace is mainly used for the casting of grey cast iron and for the casting of white or chilled cast
iron. Grey cast iron is produced by melting together low quality foundry pig iron scrapped casting and
coke in a cupola.
● In the use of cupola furnace, the possibility of steady melting of a wide range of casts irons with various
carbon and low sulfur content, including spheroidal graphite irons; better mechanical properties of cast
iron, lower sensitivity to changing wall thickness.
● The metallurgical parameters obtained in a gas cupola furnace with heterogeneous refractory bed charge
are much higher than those obtained in conventional gas cupola furnaces. When melting with the use of
charge consisting of 100% scrap iron in a gas cupola furnace, Fe burn-out is 1.47%, even when the air
heated up to 600 °C. That is almost three times higher than melting in a gas cupola with heterogeneous
refractory bed charge.
References
● Briggs, T. A. (2019). HEAT LOAD ANALYSIS FOR OPTIMAL USE OF CUPOLA FURNACE IN IRON
CASTINGS AND STEEL MANUFACTURING. European Journal of Mechanical Engineering Research, 6(1),
32-43.
● Grachev, V. (2018). Advantages of Melting Cast Iron in Gas Cupola Furnaces. Archives of Foundry Engineering,
18(3), 76-80.
● Grachev, V. (2018). PRODUCTION OF HIGH-QUALITY CAST IRON IN A GAS CUPOLA FURNACE WITH
THE USE OF INDUCTION CRUCIBLE FURNACE. International Journal of Mechanical Engineering and
Technology (IJMET), 9, 990-996.
● Nurjaman, Fajar Et al. (2018). PEMBUATAN NPI (5-8% Ni) MENGGUNAKAN HOT BLAST CUPOLA
FURNACE KAPASITAS 3 TON/HARI. Jurnal Teknologi Mineral dan Batubara 14(1), 20-26.
● Ocheri, C. (2020). Design, Fabrication and Construction of Cupola Furnace for Metallurgical Industries. Journal
of Applied Material Science & Engineering Research, 4(4), 134-141.
● Rao, P.N., 2019, Manufacturing Technology: Foundry, Forming and Welding 5 Edition, Tata McGraw-Hill
Publishing Company Limited, New Delhi.
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