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Furnaces in casting:
Melting furnaces used in the foundry industry are of many
diverse configuration The selection of the melting unit is one of
the most important decisions foundries must make with due
consideration to several important factors including:
The temperature required to melt the alloy
The melting rate and quantity of molten metal required
The economy of installation and operation
Environmental and waste disposal requirements
Several types of furnaces are most commonly used in foundries:
Cupolas
Direct fuel-fired furnaces
Crucible furnaces
Electric-arc furnaces
Induction furnaces
Selection of the most appropriate furnace type depends on factors such as the casting alloy;
its melting and pouring temperatures; capacity requirements of the furnace; costs of
investment, operation and maintenance and environmental pollution considerations.
Cupolas
A cupola is a vertical cylindrical furnace equipped with a tapping spout neat its base.
Cupolas are used only for melting cast irons, and although other furnaces are also used the
largest tonnage of cast iron is melted in cupolas.
It consists of a large shell of steel plate lined with refractory. The charge, consisting or iron,
Coke, flux and possible alloying elements, is loaded through a charging door located less
than halfway up the height of the cupola.
The iron is usually a mixture of pig iron and scrap (including risers, runners, and sprues left
over from previous castings). Coke is the fuel used to heat the furnace. Forced air is
introduced through openings near the bottom of the shell for combustion of the coke.
The flux is a basic compound such as limestone that reacts with coke ash and other
impurities to form slag. The slag serves to cover the melt, protecting it from reaction with the
environment inside the cupola and reducing heat loss. As the mixture is heated and melting
of the iron occurs, the furnace is periodically tapped to provide liquid metal for the pour.
Cupola zones
Combustion or Oxidizing zone
It is the zone where combustion takes place. It extends from the top of the tuyeres to a
surface boundary below which all the Oxygen of air is consumed by combustion, chemical
reaction that takes place in the zone is
C(coke) + 02 (from air) -> C02 + Heat
The temperature in this zone is about 1800C.
Reducing zone
It extends from the top of the combustion zone to the top of the initial coke bed. The CO2
produced in the combustion zone moves up and is reduced to CO. The temperature also
drops to 1650C.
C02 + C2 - CO Heat
Melting zone
It includes the first layer of pig iron above the initial coke bed. In this zone, the pig iron is
melted. The following reaction takes place.
3 Fe + 2 CO - Fe3C + C02
Preheating zone
It includes all the layers of cupola charges placed above the melting zone to the top of the
last charge. The layers of charges are heated by the out-going gases. The temperature in the
zone may be up to 1050C.
Stack:
It is the zone beyond the pre-heating zone, through which the hot gases go to the
atmosphere.
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