Cupola technology: key to reduced melting energy and cost
With the rising cost of electric energy foundrymen are becoming increasingly aware of the renaissance of the cupola as an efficient melting furnace for gray iron. During the past two decades a number of technical innovations have boosted the cupola to the forefront as the economical melting furnace for cast iron. Not only can the cost of molten metal be reduced significantly but metallurgical control can be achieved in ways not considered possible a few years ago. Cupola melting has advanced to new levels of sophistication and efficiency by using the following innovations: hot blast, divided blast, oxygen enrichment, projecting water cooled tuyeres, water cooled shell, improved refractories, increased cupola size, use of a single cupola, improved air cleaning, and duplexing. In the U.S., since 1968, conventional emission control equipment has included afterburners to remove carbon monoxide and oily fumes from the cupola effluent before it passes into the outside air. Unfortunately, afterburners increase operating costs and in addition consume large amounts of natural gas, which is in short supply. If, indeed, the 12 to 15 percent CO content of a normal cold blast cupola could be reduced to 4 percent or less in a properly designed oxygenation zone within the cupola stack itself, significant savings in energy would be possible. This concept has already been shown to be feasible in a laboratory cupola. Moreover, previous studies have shown that large increases in melting rate or reductions in the coke required to melt a pound of metal are possible for either cold or hot blast cupolas when operated under optimum conditions.
- Research Organization:
- Pennsylvania State Univ., University Park (USA)
- DOE Contract Number:
- EY-76-S-02-2840
- OSTI ID:
- 6898094
- Report Number(s):
- CAES-496-78
- Country of Publication:
- United States
- Language:
- English
Similar Records
Cupola furnace: state-of-the-art
Three zone energy model of cupola operation
Related Subjects
CAST IRON
MELTING
FURNACES
ECONOMICS
OPERATION
METAL INDUSTRY
ENERGY CONSERVATION
AFTERBURNERS
AIR POLLUTION CONTROL
COKE
COMBUSTION
COOLING
ENERGY CONSUMPTION
POLLUTION CONTROL EQUIPMENT
REFRACTORIES
ALLOYS
CARBIDES
CARBON COMPOUNDS
CHEMICAL REACTIONS
EQUIPMENT
INDUSTRY
IRON ALLOYS
IRON BASE ALLOYS
IRON CARBIDES
IRON COMPOUNDS
OXIDATION
PHASE TRANSFORMATIONS
POLLUTION CONTROL
THERMOCHEMICAL PROCESSES
TRANSITION ELEMENT COMPOUNDS
320303* - Energy Conservation
Consumption
& Utilization- Industrial & Agricultural Processes- Equipment & Processes