Design and Modelling of Cupola

8/9/2019 Design and Modelling of Cupola

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DESIGN AND MODELLING OF CUPOLA

DONE BY

CEASE JUNIORFIJO GEORGE

FOUZIYA C M

HAREESH MOHANAN

JESBIN JOSE

JIBIN JOSEPH

DEPARTMENT OF PRODUCTION ENGINEERING

VIDYA ACADEMY OF SCIENCE & TECHNOLOGY

THALAKKOTTUKARA, THRISSUR- 680 501


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CONTENTS

• OBJECTIVE OF PROJECT

• INTRODUCTION

• CONSTRUCTION

• CUPOLA OPERATIONS• ADVANTAGES AND LIMITATIONS

• DESIGN CONSIDERATIONS

• DESIGN

• FABRICATION DETAILS• BIBLIOGRAPHY


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OBJECTIVE OF PROJECT

• TO DESIGN AND FABRICATE A MODEL

OF SIZE 2 CUPOLA IN THE RATIO 1:2


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FURNACES

• FURNACES ARE OF TWO TYPES• 1. BLAST FURNACES

• 2. FOUNDRY FURNACES

• Blast furnaces performs basic melting operations i.e.

melting of metal ores.

• Foundry furnaces are used to casting purposes.

• Heat in a remelting furnace is created by• 1. Combustion of fuel

• 2. Electric arc

• 3. Electric resistance


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HISTORY OF CUPOLA

• DEVELOPMENT OF BLASTFURNACE FOR THEREDUCTION OF IRON OREGAVE BIRTH TO IRONFOUNDING

• AS TIME WENT ON REMELTINGOF PIG IRON FOR MAKINGGRAY IRON CASTINGS - WHICHLEAD TO THE EVOLUTION OFCUPOLA

• CUPOLA PLAYED A MAJORROLE IN THE INDUSTRIAL

REVOLUTION• FIG SHOWS STATITICS OF

FURNACES IN THE PERIOD1962-63 IN U.S AND CANADA

0

500

1000

1500

2000

2500

3000

CUPOLA

ELECTRIC ARC

INDUCTION


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CONSTRUCTIONAL FEATURES


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CUPOLA OPERATIONS

• PREPARATION OF CUPOLA

• LIGHTING THE FIRE IN THE COKE BED

• CHARGING OF CUPOLA• MELTING

• SLAGGING AND METAL TAPPING

• DROPPING DOWN THE BOTTOM


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PREPARATION OF CUPOLA

• The bottom door is dropped down and

cleaned

• Damaged firebricks are replaced

• Repairing and patching of refractory lining

• Ramming of sand bed

• Drop door is closed ,when the furnace isreconditioned


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LIGHTING THE FIRE IN THE COKE BED

• Cupola is started 3hr before the molten

metal is to be poured

• Soft and dry pieces of wood is placed over

the sand bed

• Coke is placed over the wooden pieces

• Air enters through the tuyeres• Electric spark igniters and gas torches are

also used for ignition


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CHARGING OF CUPOLA

• Charged from the charge door

• Alternate layers of Limestone (flux), Iorn,

Coke (fuel) up to charge door

• Sodium carbonate ,calcium carbide etc

also used as flux

• A metal charge would have pig iron, scrapiron, returns etc


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MELTING

• Soaking period of 30-60 minutes to

preheat

• Blast is turned on

• Molten metal accumulated at bottom


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SLAGGING AND METAL TAPPING

• Slag hole is opened, slag spouted is

collected in a container

• As air blast continues, melting progresses

and the molten iron is tapped for pouring

into the molds


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DROPPING DOWN THE BOTTOM

• All the contents are allowed to melt till one

or two charges are left above the coke bed

• Blast is shut off, the drop door is opened

and remains in the cupola is removed


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ZONES

• WELL

• COMBUSTION ZONE

• REDUCING ZONE• MELTING ZONE

• PREHEATING ZONE

• STACK ZONE


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COMBUSTION ZONE

15-30 cm above the tuyeres

1550-1850 0c

C+O2

CO2+heat2Mn+o2Mno2+heat

Si+O2SiO2+heat


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REDUCTION ZONE

• Top of combustion zone to the top of the

coke bed

• CO2+C2CO-Heat


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MELTING ZONE

It starts from first layer of metal charge to a

ht of 90 cm

3Fe+2CO

Fe3C+CO21600c


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PREHEATING ZONE

• From Melting zone to the bottom of

charging of the charge door

• 1100c

Stack zone

From preheating zone to the cupola shell

ends.• Hot gases passes escape through the

stack


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ADVANTAGES

• SIMPLE DESIGN AND EASIER CONSTUCTION

• LOW COST OF MELTING

• SIMPLE TO OPERATE AND MAINTAIN IN GOODCONDITION

• ECONOMY IN OPERATION AND MAINTANENCE

• LESS FLOOR REQUIREMENTS

• COULD BE CONTINOIUSLY MELTED

• ADEQUATE TEMPERTURE CONTROL

• CHEMICAL COMPOSITION CONTROL

• EFFICIENCY OF CUPOLA VARIES FROM 30 TO 50%.


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LIMITATIONS

• SINCE MOLTEN IRON AND COKE ARE

IN CONTACT WITH EACH OTHER,

CERTAIN ELEMENTS LIKE Si, Mn ARE

LOST AND OTHERS LIKE SULPHUR ARE PICKED UP. THIS CHANGES THE

FINAL ANALYSIS OF MOLTEN METAL.

• CLOSE TEMPERATURE CONTROL ISDIFFICULT TO MAINTAIN


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DESIGN CONSIDERATIONS

• COST EFFECTIVE

• PORTABILITY

• EASY TO HANDLE• ABLE TO EXPLAIN THE WORKING

CONDITIONS


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DESIGN

• USING THE DESIGN CONSIDERATIONS

WE ARE AIMING TO DESIGN AND

FABRICATE THE CUPOLA OF SIZE 2 IN

THE RATIO 1:2.


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CUPOLA SIZE 2 REDUCEDDIMENSIONS

SHELL DIAMETER 36” 18”

DIAMETER INSIDE LINING 27” 13.5”

MELTING RATE TONNES/HR (IRON TO

COKE RATIO 10:1)2.75 1.375

BED COKE HEIGHT ABOVE TUYERES

(in)

36-42” 18”

COKE AND IRON CHARGES (lbs) 45 & 450 22.5 & 225

FLUX (lbs) 9 4.5

Cfm AIR THROUGH TUYERES 1290 645WIND BOX PRESSURE (oz) 12 6

TOTAL AREA OF TUYERES (sq”) 118 60


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Height of the cupola 210cm

Length of the wind box 30cm

Height of the wind box from thesand bottom

30cm

No: of tuyeres 6

Wind box dia 60cmSlag hole height 20cm

Tap hole height 8cm

Charging door area 20*20=400cm2Charging door height 120cm

Charging platform height 160cm

Base platform length 60cm


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FABRICATION DETAILS

• MATERIALS REQUIRED – QTY OF GI SHEET 5 sq.metres

– QTY OF 8mm dia iron rod 21 metres

– OTY of ¾” hollow pipe 6.5 metres

– QTY of 25*25*6 angle iron 1 metre

– QTY of 6*3 ms flat 10 metres

– QTY of 50*8 ms rectangular pipe 4 metres


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MODELLING DETAILS

• First of all, we have constructed the

structure or the base to be which the

sheets have to be rolled and the legs.


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• After the construction of the base we have

gas welded the sheets, tuyeres, wind box,

spark arrester


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• Then we coated primer to it. And the

charging platform is done with the ladder.


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• Then we fabricated the inside surface of

the cupola and the painting is done.


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BIBLIOGRAPHY

• PHILIP C ROSENTHAL. RICHARD W

HEINE, CARL R LOPER, “PRINCIPLES

OF METAL CASTING”, TATA McGraw –

HILL EDITION

• Dr. O P KHANNA, “FOUNDRY

TECHNOLOGY”, DHANPAT RAI

PUBLICATIONS.


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Design and Modelling of Cupola

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