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    The document describes the basic components and functioning of a cupola furnace used for melting iron and steel. A cupola furnace consists of a cylindrical shell lined with refractory materials. It contains distinct combustion, reducing, and melting zones where iron ore and other materials are melted. Air is blown through tuyeres into the combustion zone, where heat is generated through oxidation reactions. In the reducing zone above, carbon monoxide reduces the iron oxides to molten iron that collects in the well at the bottom. The furnace operates by continuously charging materials and blowing air to produce molten iron and slag byproducts.

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    The document describes the basic components and functioning of a cupola furnace used for melting iron and steel. A cupola furnace consists of a cylindrical shell lined with refractory materials. It contains distinct combustion, reducing, and melting zones where iron ore and other materials are melted. Air is blown through tuyeres into the combustion zone, where heat is generated through oxidation reactions. In the reducing zone above, carbon monoxide reduces the iron oxides to molten iron that collects in the well at the bottom. The furnace operates by continuously charging materials and blowing air to produce molten iron and slag byproducts.

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    The document describes the basic components and functioning of a cupola furnace used for melting iron and steel. A cupola furnace consists of a cylindrical shell lined with refractory materials. It contains distinct combustion, reducing, and melting zones where iron ore and other materials are melted. Air is blown through tuyeres into the combustion zone, where heat is generated through oxidation reactions. In the reducing zone above, carbon monoxide reduces the iron oxides to molten iron that collects in the well at the bottom. The furnace operates by continuously charging materials and blowing air to produce molten iron and slag byproducts.

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    © All Rights Reserved
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    Download as pptx, pdf, or txt
    19 views37 pages

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    Uploaded by

    ananda narayanan
    The document describes the basic components and functioning of a cupola furnace used for melting iron and steel. A cupola furnace consists of a cylindrical shell lined with refractory materials. It contains distinct combustion, reducing, and melting zones where iron ore and other materials are melted. Air is blown through tuyeres into the combustion zone, where heat is generated through oxidation reactions. In the reducing zone above, carbon monoxide reduces the iron oxides to molten iron that collects in the well at the bottom. The furnace operates by continuously charging materials and blowing air to produce molten iron and slag byproducts.

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    • Metal ore ----- PIG IRON--- to produce Wrought iron
    • 30meter high and 8m diametre.
    • Fire proof bricks
    • Hot air passed from the bottom

    Wrought iron:
    A tough malleable form of iron suitable for
    forging or rolling rather than casting, obtained by
    liquid pig iron while molten. It is nearly pure but
    contains some slag
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    in the form of filaments.
    • Due to Density difference the molten metal flows down.
    • Coke, limestone and iron ore are poured at the top.
    • Air is blown in through tuyers.

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    Before Reduction After Reduction

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    • 4. blast furnace science
    • MT\unit 1

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    • Used to produce gray, nodular cast iron
    • Also used for melting copper base alloy
    • Fuel for cupola is good grade low sulphur coke, anthracite
    coke(hard and rich carbon).

    Nodular cast iron

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    • Cylindrical shell welded or riveted 10mm thick plates.
    • Open at both top and bottom lined with firebricks and clay.
    • Castlron leg supports it.
    • At bottom a swing door helps to left the content after the
    melting.

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    • Air from the blower comes form the blast pipe and enters wind
    box. And supply evenly to all tuyeres.
    • Tuyeres extend by a steel shell and refractory wall to the
    combustion zone and supply air.
    • A 75cm dia cupola have 3-4 tuyeres.
    • Volume meter helps to measure the volume of air passing to the
    combustion zone.

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    • Air pressure is 12-16 sq in.
    • A cupola uses 10:1 ratio of iron to coke.
    • About 800-900 cubic meters of air is used to melt one ton of
    iron.

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    1. Preparation of cupola.
    2. Lightning the fire in the coke bed.
    3. Charging of cupola
    4. Melting
    5. Slagging and metal tapping
    6. Dropping down the cupola bottom

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    1) Preparation of cupola:
    • Bottom door is dropped – dumped unburned coke , slag are
    removed – side wall cleaning – replace damaged firebricks.
    • Cupola block composition
    Silica 52-62% Alumina 31 – 43%
    Titania 1.5-2% Fluxing oxides 3-6%
    Bottom door closed- 10cm sand is rammed have some sloping
    towards tap hole.

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    2) Lighting the fire:
    •
    • Ignited in Dry wooden pieces(OR electric, gas tourches), air is
    supplied to burn coke.

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    3)Charging of cupola:
    • After the ignition form charging door addition of alternate
    layers of COKE, Flux (limestone), and IRON is supplied upto
    the level of charging door.
    • Flux used to remove the impurities
    • Coke- good low sulphur coke, anthracite coke
    • Iron: pig iron, scraps, returns (gates, sprue, risers, defective
    castings)

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    4) Melting:
    • Initially one hour takes for preheating the charge.(soaking
    period)
    • Now the air blast is turned on.
    • After ten minutes molten iron starts accumulating near the tap
    hole.

    Combustion system Reducing zone


    C + O2 ——→ CO2 + Heat CO2 + C (coke) ——→ 2CO + Heat
    Si + O2 ——→ SiO2 + Heat
    2Mn + O2 ——→ 2MnO + Melting zone
    Heat 3Fe + 2CO ——→ Fe3C + CO2
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    Combustion system
    C + O2 ——→ CO2 + Heat
    Si + O2 ——→ SiO2 + Heat
    2Mn + O2 ——→ 2MnO +
    Heat

    Reducing zone
    CO2 + C (coke) ——→ 2CO + Heat

    Melting zone
    3Fe + 2CO ——→ Fe3C + CO2
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    5) Dropping down the bottom:
    • At the end the charging is stopped.
    • All the contents in the cupola is allowed to melt.
    • Air blast is shut off.
    • The prop in the bottom door is knocked down.
    • And quenched in water and use in the next heats.

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    6) Slagging and metal tapping:
    • After enough molten iron collected the slag hole is opened and
    it is collected and disposed off.
    • The bolt inserted in the tap hole is knocked out and the first
    molten iron is cast with ladled and poured into the moulds.
    • Charging is done simultaneously by layers.

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    • 5. Cupola Furnace
    • :\MT\unit 1

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    • 1.Well:

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    • 1.Well:
    • The space
    between the bottom of tuyers and the
    sand bed inside the cylindrical shell of cupola is called as
    well.

    • Molten metal is collected in this portion.

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    • 2.Combustion zone:

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    • 2.Combustion zone OR Oxidizing zone:
    • It is located Upper of tuyers.

    free oxygen via air blast and


    • Consuming of
    produces tremendous heat.
    • Due to oxidation process occurs in silica and manganese
    additional heat is generated. (1540°C to 1870°C )
    • C + O2 ——→ CO2 + Heat
    • Si + O2 ——→ SiO2 + Heat
    • 2Mn + O2 ——→ 2MnO + Heat

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    • 3.Reducing zone OR protective zone:

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    • 3.Reducing zone OR protective zone:
    • It is located in upper level of combustion zone.
    • Here CO2 moves upwards and reacts with Coke and
    reduced to CO + heat as an endothermic
    reaction.
    • CO2 + C (coke) ——→ 2CO + Heat
    • This reducing atmosphere protected this zone against oxidation.

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    • 4.Melting zone:

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    • 4.Melting zone:
    • The charge(iron ore, limestone, coke) starts melting in this zone
    and trickles down through coke bed and collected in well.
    • Here carbon content is picked by molten metal
    3Fe + 2CO ——→ Fe3C + CO2

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    • 5.Preheating zone:
    • Here alternate layers of coke bed, flux and metal charge are
    there.
    • Preheating done here (room temp – 1090 deg)

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    • 6.Stack:

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    • 6.Stack:

    • The empty portion of cupola above the


    preheating zone is called as stack.

    passage to hot gases


    • It provides the
    to go to atmosphere.

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    • Slag is the glass-like by-product left over after a desired metal
    has been separated (i.e., smelted) from its raw ore. Slag is
    usually a mixture of metal oxides and silicon dioxide. However,
    slags can contain metal sulfides and elemental metals.

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