METHODS OF MELTING

Anil Kumar. Garikapati

INTRODUCTION
 There are a no of methods available for melting the
foundry alloys such as,
 Pit or crucible furnace,

 Open hearth furnace,

 Rotary furnace,

 Cupola furnace,

 Electric furnaces,

 The choice of the furnace depends on the amount and the

type of alloy being melted.
CUPOLA FURNACE
 Cylindrical type of furnace for producing molten CAST iron,
 Lined with heat resisting (refractory ) bricks.

 The shell is made of steel plate of 8mm to 10mm.

 Dimensions of a cupola:
 The c/s area of a cupola depends on the o/p of the molten
metal. And is det. By using the following formula:=Ac
 The height of the cupola is taken 3 to5 times the diameter of
the cupola.
 The common dimensions of the cupola are;

1.Outside dia- 900 to 2700mm

2.Inside dia - 500 to 2100mm
3.Height- upto12m
 Pig Iron
(main
charge)
Feldspar Iron waste

Foundry
Sulphur
Ingredients waste
used in
Cupola

Manganese Scrap

Silicon Carbon
VARIOUS ZONES OF CUPOLA

Well or crucible.

Tuyer zone.

Combustion zone.

Reducing zone.

Melting zone.

Preheating zone
COMBUSTION ZONE
 Combustion if fuel takes place by oxygen of air blast &
produce lot of heat.
 The reaction is Exothermic and the highest temperatures
are developed in this zone.
 The temperatures may reach 1600 degrees to 1700
degrees.
 These heat transferred to other parts of the furnace.

 Carbon, silicon & manganese are oxidised to produce

heat.
 The reactions are,
REDUCING ZONE
 The Co2 Flowing upwards through this zone reacts with
hot cocke and the reaction is endothermic.
 The reaction is ,

Co2 + C (coke) -> 2Co – Heat.

 Because of this reaction , the temperature in the
reducing zone gets reduced to about 1200 degrees.
 However , the metal charge (iron and other elements )
above will be protected from oxidisation.
MELTING ZONE
 This layer includes the the first layer of iron above the
initial coke bed.
 In this zone ,the charge starts melting and trickling
through the coke to the bottom of the cupola,
 A significant of the carbon pick up by metal also occurs
in this zone.
 The reaction takes place is,

3Fe + 2 Co  Fe3 C +Co2

OTHER ZONES
 Preheating zone:-
Includes Charge And get preheated
Moisture and volatile matter are evaporated
The temperatures are here are 1090 degrees
 Well:-

The molten metal gets collected here

This also known as Crucible
 Stack:-

Carries the combustion gases

DESCRIPTION
 Shell
 Spark arrester

 Refractory lining

 Charging door

 Charging platform

 Wind box or blast pipe

 Tuyeres

 Slag spout

 Sand bottom

 Tap hole

 Legs & prop

 Fuel

Metallic
Fluxes
materials

Charge
CHARGE
 Metallic materials
Pig iron of various grades.
Cast iron ,&
Steel crap,
Foundry scrap.
 Fuel

Foundry coke
Anthracite coke .
 Fluxes

A flux is a substance which react with slag(accumulations of

oxides and other unwanted materials)to lower its melting points
The fluxes used are Limestone, Dolomite
OPERATION
 Should be thoroughly dried before drying
 A layer of sand (150mm) is placed over the doors and sloped
towards the tap holes
 Initially the kindling wood is fired

 Coke bed is made (700 to 800mm)

 Then coke and charge is added alternatively

 The tuyeres are opened gradually to intensifies gradual combustion

 Lime stone =2 to 4%

 Coke= 8 to 12 % , &

 The metal is added alternatively

 The first molten metal would appear in the tap hole within 10 to 15
minutes
 When the well or the crucible is filled the slag is first drained off.
 • Initial cost is low compared to
other
• Maintenance is easy and economic
• Operation Cost is low
• Low space is required compared to
other
• Run for long time
• Composition of the melt can be
controlled
• Temperature of the melt can be
controlled

Limitations
• Metal purity cannot be maintained
• Temperature is difficult to control
CRUCIBLE FURNACE