SOME IMPORTANT CALCULATIONS

1) CUPOLA: Coke-bed charge calculation

If a cupola is examined after dumping the remains through the bottom door, a groove can be
seen in cupola lining. This groove shows the location of high temperature zone. The coke
bed charge should reach the height of this groove above the sand bottom.
i) Cupola diameter = d = 75 cm
Height of groove above the sand bottom = h = 150 cm
Find the weight of the bed charge if the coke weighs = w = 482
kg/m3.

Solution
Weight of the bed charge
W=π/4 d2 . h . w = π/4 (75/100)2 . (150/100) . 482
W= 320 kg

2) CUPOLA: Melting Rate

ii) A Cupola 75 cm in diameter has a melting ratio 10:1. How much
iron is melted per hour? How much coke is consumed per hour?
Assume melting rate of 0.562 kg/hr/cm2 .

Solution
(a) Iron melted per hour
W1=π/4 d2 .melting rate (d=75cm, mr=0.562 kg/hr/cm2)
W=π/4 (75)2 . (0.562) = 2480 Kg/hr.
(b) Coke consumed per hour = 2480/10 (melting ratio 10:1)
= 248 kg/hr
3) CUPOLA: Charge Calculations
A cupola charge weighs 1000 kg and is made up of the constituents of the following proportions
1. Carbon
Weight of the element (such as C or Si) in a constituent (such as Pig
iron no1) of the cupola charge =
(weight of the total charge) * (proportion or fraction of constituent in
the charge) * (fraction of element in the constituent)

Pig iron # 1 : 1000 * * = 5.25 kg

Pig iron # 2 : 1000 * * = 7.00 kg

New scrap : 1000 * * = 10.20 kg

Shop return : 1000 * * = 11.55 kg

Total = 34.00 kg
Thus percentage of the carbon in the final analysis would be
= *100 = 3.4%

Similarly other calculations can be done for Si, Mn etc