CONTENTS

Page No.

1. Introduction
1

2. Conventional cupola
2

3. Divided blast cupola

8

4. Air Supply System

12

5. Raw Material
17

6. Cupola charge calculation

20

7. Refractory
22

8. Front Slagging Spout

26

9. Cupola Instrumentation
28

1
 10. Cupola operation
31

11. Cupola Troubleshooting

32

12. Cupola log Sheet

34

13. Process Failure Factors

36

INTRODUCTION

Cupola is very versatile melting unit. With the advent of modern cupola
design, instrumentation and cupola opearational techniques ,it is now
possible to get high strength cast iron, alloy cast iron and even S.G.
iron from the cupola . In recent years world class raw material such as
Pig iron, coke are now available in India. We also now get better
refractory which can withstand at higher temperatures for longer
durations .However, it is observed, that, most of the cupola units are
not taking any advantage of these modern facilities and are still
following the age old design and practices.

This cupola ready reckoner is prepared specially for all the foundrymen
, cupola operators and supervisers to get the ready made cupola data
at their finger tips. The important facts are given in the form of charts,
tables and figures. Also very important details, such as, Conventional
and Divided Blast Cupola structural details and front slagging spout
preparartional details are given. Specifications of pig iron, coke,
limestone, bricks etc are also included. Moreover, most neglected

2
areas like blower and instrumentation are, dealt in, length to
emphasise their importance.

It has been observed that many cupola units fail to get optimum
results even after modernization of the system . This is due to the
failure of adopting the technology in toto. To understand this, Process
failure factors are also given.

I am sure that foundrymen will find this ready reckoner very useful.

Mrs.
S.S.Karkhanis

Conventional Cupola - sectional view

3
Fig. 1

4
CUPOLA- VARIOUS ZONES AND TEMPERATURES

5
 Fig.2

CONVENTIONAL CUPOLA - VARIOUS PARTS WITH DIMENSIONS

6
 Table-1

GENERAL RECOMMENDATIONS FOR CUPOLA OPERATION

Cupola She Dia Melting BED Coke Iron Lim CFM Suggested
Size ll insid Ratetons/h coke char Char e Air Blower
Dia e rwith height ge ge Ston Thro selection
Linin coke:iron above Kg e ugh
g 1:10(betwe tuyers Tuye
en the inches rs
charges)
CFM Dischar
ge
Pressur
e
(WG)in
ch
0 27” 18” 1 28-44 10 100 2 570 640 14

2 36” 27” 2 ½ 36-42 20 200 4 1290 1430 34

3 50” 36” 4½ 40-46 45 450 22 2420 2700 40

4 56” 42” 7 42-48 70 700 35 3100 3450 40

6 66” 48” 9 45-51 90 900 45 4100 4500 55

7 72” 54” 11 45-51 110 1100 50 5200 5750 55

8 78” 60” 14 45-51 140 1400 70 6400 7100 55

Table -2

1.For long heats use heavier lining

7
2.Height of bed coke varies as square root of blast pressure H=10.5+
√P

3.Additional pressure capacity may be required when auxiliary

equipment is added to the blast system or when piping is long or
complicated

4Under normal conditions metal temperature will decreases as iron to

coke increases

High Efficiency Divided Blast Cupola ( DBC )

Divided blast cupola is a modification of the conventional cupola. HOT BLAST
CUPOLA - For the improvement in the metal temperature of the conventional
cupola at the spout, earlier hot blast cupolas were being used. The idea was to
take away the unburnt gases from the cupola stack and burn it. The heat thus
developed was used to pre- heat the air that was subsequently supplied to cupola.
Thus, maximum heat was developed. However there are many constraints to the
use of hot blast cupola, such as, initial cost,material and maintenance etc.

DIVIDED BLAST CUPOLA - The divided blast cupola has one additional wind box
with row of tuyers i.e. upper row of tuyers and hence extra air is supplied at a
higher level. This extra air burns the unburnt carbon monoxide produced at the
bottom tuyers , thus developing additional heat, resulting in higher metal
temperature at the cupola spout. To get the desired results (1) Metal Temperature
(2)Melting Rate (3)Coke:Metal Ratio and (4)Trouble Free Cupola Operation, it is
necessary to design the DBC taking into consideration all the technical aspects
very meticulously.

With Divided Blast cupola design following results can be obtained:

(1) Metal temperature at the spout : 14500C to 15200 C

(2) Steel scrap addition : up to 40 %

(3) Metal:coke ratio: 8%

8
 (4)Melting rate:.9-tons/sq ft/hr as against .6-ton/sq ft/hr of
conventional Cold blast cupola

(5) Operation period : up to 24 hours to 30 hours without water

cooling for bigger cupolas

(6) Due to addition of steel, use of special pig iron and home scrap, it
is positively
possible to control ‘P’ and ‘S’ content of the metal.

Thus the advantages of divided Blast Cupola are as follows:

a)Reduction in coke consumption of about 20 percent for same tapping
temperature
b)increase in melting rate with same coke consumption
c)Divided blast without reduced coke consumption can give an increase I
tapping temperature of up to 50°C and
d)The reduced coke charge enables output rates to be increased upto 20
percent without increasing the normal blast rate
e)Reduction in carbon monoxide in exaust gases, thus reducing pllution

9
DIVIDED BLAST CUPOLA-SECTIONAL VIEW

10
Fig.-3

11
Recommended Dimensions for Divided Blast Cupola

Sr. Characteristic Designation of the furnace

No.

1 Cupola 600 750 900 1050 1200 1350 1500 1650

diameter,inside,
after lining at
the hearth mm
2 Lining Thickness 150 150 150 200 200 200 200 250
in melting zone
mm
3 Sand filling mm 15 15 15 15 15 15 15 15

4 No. of tuyers in 4 4/5 6 6/8 8 8/10 10/12 12

each row
5 Total Tuyer
Area,cm² for
tuyer ratios 940 1470 2120 2800 3770 4770 5890 7130
a. 1:3 705 1105 1590 2165 2825 3575 4100 5340
b. 1:4 565 885 1270 1730 2260 2860 2530 4275
c. 1:5 470 735 1060 1440 1885 2365 2945 3360
d. 1:6

6 Blat Pipe Dia 200 250 300 325 350 375 400 425

7 Motor Power 7.5 10.0 18.0 25.0 35.0 45.0 60.0 70.0
H.P.
8 Melting Rate 3.0 4.2 6.0 8.4 10.8 13.8 16.8 20.4

9 BLAST Pressure 43 46 48 50 52 54 56 58
WG cm
10 Blast Volume 25 33 54 80 118 158 196 240
m3/min

Table 3

12
Comparision of CO-CO₂ Gas produced in conventional and
divided blast cupola

Com
V
Fig -4

In conventional cupola when fresh air enters in the primary tuyers, it

contains about 21% of Oxygen. As the air rises at higher and higher
levels, more and more oxygen is converted into carbon dioxide gas.
Thus Oxygen reduces and carbon dioxide increases. At certain level,

13
 oxygen contents becomes zero. Here part of the carbon dioxide starts
converting into carbon monoxide. Hereafter, both carbon monoxide
and carbon dioxide coexists. Finaly, the exaust gases contains about
11% CO₂ and about 18% CO.
In DBC in addition to primary tuyers , we introduce extra oxygen at
secondary or top tuyers, thus oxidising the carbon monoxide to carbon
di oxide. Hence, the effluent gases contains about 18% of CO₂ and
about 2% of CO.
This burning off of carbon monoxide, develops heat in the cupola
stack, incraseing the metal temperature at the spout. Further, this
reduction in CO, helps to attain Pollution Control norms.

Comparison of Coke Consumption - Conventional and

Divided blat cupola

Fig. – 5

14
 The fig.gives the graph of temperature against the coke consumption
in %. The melting rate is given in the bracket with the coke
consumption percentage.
The figure Shows that , to achive particular temperature level, DBC
needs less coke and at that temperature the melting rate of DBC is
more as compared to that of the conventional cupola.

CONVERSION OF CONVENTIONAL CUPOLA TO DBC

1. If the conventional cupola structure and shell is good and sturdy
2. If the conventional cupola system including the blower and ducting are as
per recommended standards

Then this cupola can be converted to DBC as follows:

1.By addition of one more wind box

2.By addition of extra blast pipe
3. By addition of extra row of tuyers
4.By addition of extra instrumentation

Air Supply System of Cupola

1. BLOWER

Selection of proper blower is most important step in the set-up of cupola. Blower
must be purchased from a reputed manufacturer. Before taking the delivery of the
blower, its air pressure and air volume must be checked as per BIS standard tests.
It is also vital to check the balancing of the impellar.

Trouble Shooting for Blower

A. The motor starter cuts out on overload:
1. Check overload relay for under rating,
2. wrong installation,
3. one phase not powered,
4. too much air being taken from the blower and
5. over greesed bearings

15
 B. The blower does not develop design pressure
1. Check blower running backward
2. Operating at high altitude
3. Restriction at inlet, such as under size duct or dirty filter
4. Gasket at outlet restricting flow
5. Low motor speed
6. Low voltage
7. Lower cycle current than for which the motor is rated
8. Drive belt loose

C. Noise
1. Check impeller hitting inlet ring cutoff, pulleys not tight on shaft, belts too
loose
Belts too tight, pulleys is aligned, motor and fan belt s loose.
2. Bearings defective, needs lubrication,
3. Impeller loose on shaft, defective impeller, unbalanced impeller, worn out
impeller
4. Foreign material in housing
5. Leak in ducting
6. Vibrating duct work, vibrating parts not isolated from building

D. CFM low

1.Forward curved impeller installed back ward, Fan running back ward, cutoff
missing or i
improperly installed, fan speed too low
2. Damper partially opened, leaks in supply duct
3. Elbows or other obstructions restrict air flow no straight duct at fan outlet,
sharp bends
in ducting, improperly designed turning vanes

E. CFM high

1. Oversized duct work,

2. access door open,
3. fan speed too high

F. Static Pressure low, CFM high

1. System has less resistance to flow

2. Pressure will be less with high temperature or at high altitude
3. Backward inclined impeller installed backward ( HP will be high)
4. Fan speed too high

16
 G. Static Pressure low, CFM low

1.Fan inlet and outlet conditions not same as tested

H. Static Pressure High, CFM low

1. Obstruction in system,
2. dirty filters, dirty coils,
3. System too restricted

I. HP High

1. Backward inclined impellar installed backward

2. Fan speed too high
3. Oversized duct
4. Fan not operating at efficient point of rating

Maintenance of Blower

Remove dust from impeller and casing once a year in general and more
frequently where environment is dust laden

Motor bearings may require lubrication, jackshaft bearings should be

greased every six months .
Replace coupling pad or tyre once a year.

Replace V-belts once a year, check V-belts tension daily, Loose V-belts will
reduce blower speed, increase belt friction causing heating of motor and
bearings
2.Blast Pipe

Blast pipes supply air from blower to cupola. For minimum loss of air in the
system,

1. the size of the pipe should be adequate.

2. Pipes should be straight and
3. with minimum bends and branches
4. Butterfly valves should be provided in the pipes for controlling
air
5. There should be no leakages in the blast pipe to avoid loss of
pressure

17
 Fig - 6

3.Wind Box

18
The purpose of wind box is to nullify the pulsations of the air and to supply air
continuously to cupola.The area of wind box should be at least four times that of
area of blast pipe.

Fig - 7

19
4. Cast Iron Tuyer
Cast Iron tuyers must be used. Cast iron tuyers ensure fix size of the
tuyer during the heat.
The cast iron tuyers also make certain that desired volume of air
enters into the cupola, as there are no leakages of air through the
lining . The ribs of the tuyers are to be bolted to the cupola shell from
inside as shown in the picture below..

20
 Fig - 8

RAW MATERIAL
The raw material used in cupola is (1) Pig Iron,(2) C.I. Scrap, (3)Steel Scrap,
(4)Coke and (5)Lime Stone. It is necessary to know the chemical compositions/
properties of these material for the production of desired grade of cast iron.

Typical Chemical Composition of Pig Iron

Grade I II III

SI 1,5 %- 1.99% 2% 1.0 % to 2 %

C 3.8 % - 4.2% 3.8 %- 4.2% 3.8 %-4.2%

Mn 0.5% Max 0.5 % max. 0.2 %

P 0.08% max 0.08% max. 0.065 % max

S 0.05 % max 0.05 % max. 0.02 % max

Table – 4

Typical composition of cast iron scrap

Type Total Silicon% Manganese Sulphur% Phosphoru
Carbon% % s%

Ingot mold 3.4 -3.7 1.4 -1.8 0.5- 1.0 0.08 0.1
scrap

Heavy C.I. 3.1-3.5 2.2-2.8 0.5-0.8 0.15 o.5-1.2

Scrap

Medium 3.1- 3.5 2.2- 2.8 0.5- 0.8 0.15 0.5-1.2

C.I.Scrap

Automobile 3.0—3.4 1.8-2.4 0.5-0.8 0.15 0.3 max

Scrap

21
 Table - 5

Typical Properties of Foundry Coke

SIZE 10 % of cupola I.D.

Volatile Matter 0.5 to 1.5 %max

Total Moisture 00.5% max

Porosity 45 to 50%

Ash Content 12 % max

Sulphur 0.5 to 1 % max

Phosphorus 0.1 % to 0.2 % max

Shatter Index 85 min

M20 Min 90

M10 Max 8

CSR 64-74

Gross Calorific Value KCAL/KG 6800

Min

Min Size 100 mm

Table - 6

Typical composition of Lime Stone

Cao 52% Min

Sio2 <2%

P2O5 <.04

Al2O3 <2%

Insoluble Residue 2 to 4 %

22
 Table - 7

Effects of Substandard/ Inadequate Raw Material on Casting

Quality

Raw Irregularity Immediate Effect Effect on metal

Materi
al

Pig Composition not Variation and Metal of consistent quality

Iron specified incorrect can not be obtained

Batches not Metal composition

segregated stock
yard

C.I. C.I. Scrap of variable Charge composition Metal not to specification

Scrap composition not correct

Scrap piece too Bridging and

Variable in metal Temp and
large uneven melting
composition
Contamination of
Problems due to trace
metal
Non ferrous parts in elements such as pin holes.
scrap Low strength, cracking,
chill,
Heavily painted
scrap

23
Steel Grade not specified Contamination of Defects due to trace
scrap metal with trace
Pieces of nonferrous elements
elements
metal
Chill and increased
Pieces of stainless
hardness
steel

Ferro Composition and Ferro alloy pieces Hard spots on machining

alloys grading requirement too long not to be
not specified dissolved

Table - 8

SIZE OF METALLIC CHARGE

Thin section steel scrap below 0 .5mm oxidizes rapidly, and increases melting
losses. On the other hand very thick section steel, over 75 mm, may not
completely melt in the cupola. Metal pieces should not be longer than one third
of the diameter of cupola, to avoid scaffolding of the charge

KEY INPUT ( Raw Material ) VARIABLES

Steel – Charge weight, size, thickness, surface area, cost, %C, %Si, %Mn, %S, %
rust.

Cast Iron - Charge weight, size, thickness, surface area, cost, %C, %Si, %Mn, %S,
% rust.

Alloys – Charge weight, size, % alloy, composition, % binder and other materials,
binder

composition.

24
Coke – Charge weight, size, % carbon, % ash, % sulfur, reactivity, apparent
density, cost.

Limestone – Charge weight, size, % CaO.

Blast Air – Rate, temperature, humidity.

Cupola charge calculation

In normally operated cupola the composition of the metal tapped can be predicted with
reasonable accuracy, from the composition of charge. The tendency of the carbon is to
attain the eutectic composition ( 4.2 % total carbon ). If the quantity charged is above this
value, a loss may be expected .On the other hand, if the charge contains less than the
eutectic value, the trend is towards CARBON PICK - UP.

The LAVY EQUATION IS :

TC% at spout=2.4+TC % in the charge2+Si% +P% at spout4

Silicon is always lost in cupola, generally a loss of 15% of that charged may be assumed,
but higher losses may occure if oxidation takes place. Manganese losses are about 25%.
Phosphorus changes little. Sulphur always increases due to pick up from coke, but
precise amount cannot be predicted.

To make a grade 250 iron with the composition of :

TC Si Mn P

3.2 % 1.7 % 0.7% 0.1%

Following Table can be used :

Material Amou Composition Contribution to Charge %

nt
Charg
ed %
TC Si Mn P TC Si Mn P
Low P Pig 25% 3 3 1.0 0.1 X .75 .75 .25 O.O3
iron 0.25
Grade 250 35% 3.2 1.7 0.7 O,1 Xo.35 1.12 .60 .25 0.04
Returns
Iron Scrap 15% 3.2 2.2 0.8 o.15 X0.15 .48 .33 .12 0.02
%
Steel Scrap 25% .1 .1. 0.3 0.03 X .25 .03 .03 .08
0.25
%

25
Ferromangan 0.3 75 X0.00 0.23
ese 3
TOTAL 2.38 1.71 0.93 0.09
Changes Si loss 15% -
during Mn loss 25% 0.26 -
melting 0.23
Addition at 70% ferroSilicon +0.2
spout 5
Expected TC= 2.4+2.38/2-
Composition (1.45+0.09)/4
= 3.2
Si = 1.7
Mn=.70
P =0.09

Table – 9

Calculation such as above should only be used as guide. The

precise Carbon pick up depend on factors such as coke quality,
Metal Temperature, Melting rare etc.

Refractory

Type of Refractory

26
 Fire Brick
applicatio
S. Qualit Specifications
n Area
No y
Al₂O₃ Fe₂O₃ A.P. BD Min CCS RUL(T
% % % A)
Gms/c Kg/c
c m² °C
1 IS 6 30 3.5 26 2 250 1300 Cupola
Stack,cup
ola outer
layer
2 IS 8 40 3.5 25 2.1 250 1350 Cupola
preheatin
g Zone
3 High 40 3 24 2.5 300 1400 Cupola
Duty melting
zone back
up layer
4 Super 60 1.5 20 2.5 450 1500 Cupola
Duty melting
zone,
cupola
well

Table - 10

Direction for Lining

Bricks should be dipped in thin fireclay morter and laid.I t is recommended to leave
gap of about ¼” to ½ between the cupola shell and outer course of brick layer.
This is to take care of the expansion of bricks. This gap should be filled with

27
moulding sand. Tuyers should be fitted tight against the shell to minmise air
leakage. If cupola is to be used for long heats, it is advisable to use a heavier
lining.

Daily Repairs:
The cupola lining at the melting zone should be chipped free of slag and coke after
each run and the lining repaired to its original diameter. Any accumulation of slag.
coke, or iron in the tuyere elbows must be removed daily. The slag hole, tap hole,
slag and spout should have daily attention..

The sand bottom for long heats should be deeper than for regular operation. A
good grade
of daubing should be used in patching the lining. Failure to chip out the slag
thoroughly after a heat and before applying daubing will result in slag becoming
soft when iron begins to melt. Carrying the daubing away with it and exposing the
lining to further cutting by the iron and slag.

Attention should be given when putting a sand bottom on a rainy day. If water gets
in the cupola, the bottom will get wet, causing the iron to boil, which may damage
the sand bottom.

End of the Heat:

As the heat nears the end, the blast should be reduced and stopped altogether as
soon as the
cupola is dry. Otherwise the lining will be burned out much more than necessary.

Ramming Mix or Patching for cupola lining

Crushed firebrick 5/16 + 40

20 mesh %

Fine Silica Sand 40

%

28
 Fireclay of maximum 20
refractoriness %

Moisture 7
%

Table – 11

Botting Mixture (Table – 12)

Suitable for small botts and frequent tapping

Fireclay (30-50 % on clay grade)- 70-88 %

Coal Dust(11% ash max. superfine 10% to 20 %

grade)-

Suitable where long gathering periods and large tap hole is

employed(Table – 13)
Fireclay (as Above) 50%

Coal Dust 10% - 20%

Black Sand 20% - 38%

29
 CUPOLA SIZE AND REFRACTORY CONSUMPTION
CUPOLA SIZE T/H LINING FLUX INEVITABLE SLAG% OF
I.D. R CONSUPTION USED SLAG METAL

% OF METAL

84”I.D. 40 .5 % 1.9 % .76 % 2.4 %

T

48”I.D. 1.5 % 3.5 % 3.31 % 4.8 %

12
T
36”I.D. 5T 3.0 % 5.5 % 9.77 % 13.77 %

Table – 14

SLAG is formed of following material :

Lining ware out

Coke ash

Silica (Sio2 )

Manganese oxide ( Mno2 )

Dirt on srcap

Refractory consumption in Indian Conditions is 7 Kg to 8

Kg /ton of metal

FACTORS RESPONSIBLE FOR LINING WARE OUT

1. Duradtion of heat

2. temperature of metal

30
3. degree of oxidation

4. excessive air blast at high pressure

5. uneven supply of blast

6. irregular charging and bridging- permeability

7. too much tuyer area

8. insufficient tuyer area

9. uneual tuyer dimention

10.excess flux

11.insufficient flux-low permeability

12.careless charging of flux

13.use of fluospar and calciuam carbide

14.high % of steel scrap

15.thin and rusty steel scap

16.thin ,oxidized, burned scrap

31
 FRONT SLAGGING CUPOLA SPOUT

Fig. 9 : View of Front Slagging Spout

32
Fig. 10 : Cross Section of Front Slagging spout

Dimentions of Front Slagging Spout

Cupola Pressure in WG “H” in inches “S’ in inches

7” 1 1¼

14” 2 1¼

21” 3 1¼

27” 4 1¼

34” 5 1¼

33
 Table - 15

INSTRUMENTATION For CUPOLA

When pressure gauge and volume meter are installed side by side on the cupola
panel board then the conditions inside the cupola can be judged at a glance only

34
Fig - 10

Fig - 11

Fig - 12

35
 Fig - 13

36
Installation of Instrumentation for DBC

37
 Fig - 14

Cup

38
Figure 15

Cupola Operation

The Coke Bed

Proper coke bed ignition is important for the quality of the metal to be produced.
Melting rate and metal temperature are functions of the initial height of the coke
bed above the tuyeres and the degree to which the bed is burned in. The
mechanism by which melting is accomplished in the cupola is heat released by
combustion of carbon through the reaction of air ( oxygen) and coke (carbon).
Sudden changes in metal temperature during a campaign would indicate that the
coke bed is too low. Facilitating the proper air/coke mix provides more uniform,
hotter coke burning. Given the opportunity, selecting uniformly large chunks of
coke provides greater void areas in the bed and improves the penetration of the
air blast and the volume of molten metal in the well.

39
Initially, the bed is laid- up to the tuyere level, and gas or oil igniters are inserted
through ignition ports or tuyeres just above the sand bottom, taking care to reach
the bed's center. Once the bed is uniformly ignited, additional coke is added.

The two steps to bed preparation, ignition and burn-in, are mainly a function of
materials at hand and foundry preference. Other bed considerations include
additions, consolidation and measurement.

Burning-in

After the first portion of the coke bed is thoroughly ignited, additional batches of
coke are added until the top of the bed is just below the required height. The
tuyeres are closed and the blowers turned on briefly to complete the ignition. The
bed should be closely observed to ensure that it has been properly burned in and
the coke bed prodded to consolidate the bed and eliminate voids. Consolidation
reduces the bed height somewhat, and it should be gauged from above using a
bed measuring-rod or chain. More coke is added to bring the bed up to the desired
operating height.

Cupola Trouble Shooting(Table – 16)

S.NO Trouble Causes Remeady

1 Scaffolding in the
stack
1Scrap of larger size 1Do not use scrap more
is charged than 1/3 diameter of
cupola
2 stack height is too
high 2.charge only 5 to 6
charges on the coke bed
3. blast pressure is
and maintain this level
low
through out the heat

3.in case of scaffolding

blow cupola strongly till

40
 the scaffold comes down

2 Bridging at Viscous and sticky 1. Increase coke bed

melting zone slag adheres to the height
cupola lining. 2. Increase lime
Additional sticky stone
droplets reduces the 3. Use soda bricks
internal dia. Of
cupola, making it
difficult for melt to
come down.

3 Choking of tuyers 1. Metal entering 1. Metal level in

in to tuyer intermittent cupola
2. Slag freezing should be
infront of tuyers controlled
judiciously
2. Supply of air of
every tuyer should
be cut in turn for
5-10 minutes. This
will heat up the
tuyer and it will
become red hot
again

4 Initial cold metal 1. Preheating of 1. Do proper

charges not preheating of
sufficient charges
2. Bed coke low 2. Check bed height
3. Bed coke high before stating to
charge
3. Reduce or increase
coke between the
charges as per
requirement of
correcting the bed
height
4. Increase or
decrase air volume
to improve metal

41
 temperature

5 Low metal 1. Bed coke low 1. Correct bed height

temperature 2. Bed coke high with correcting
3. Low coke coke charge
charge 2. Check air pressure
4. Improper air and air volume
supply
5.

6 Oxidised metal 1. Low bed coke 1.Reduce air

2. Excess air
2. Add booster coke
charge

7 Shell getting red 1. Thin refractory 1.Use double lining

hot lining for long for long heats
heat
2. Use recommended
2. Improper
refractory in the
selection of
particular zone
refractory i.e.
refractory with 3.Do not leave cracks
less while repairing the
refractoryness cupola
is used
3. Refractory 4. Cracks developed
repairs are not in the lining during
proper drying shold be
patched properly

8 Fluttering of metal Spout dam height is 1. Reduce height of

at front slagging high,thus causing tap spout dam
spout hole partially open 2. Make a template
to prepare spout
and use it
regularly

9 Slag hole size 1. Slag hole taper 1 incrase slag spot

increase in botting is less taper

42
 type spout 2. Slag hole is not 2.If the slag hole is
welded incrsed during the
properly after heat, repair and
earlier heat weld it properly
before next heat

CUPOLA MELTING LOG SHEET

Name of Company:

CUPOLA TYPE: Divided Blast Cupola Size: Date:

TIME RECORD AM/PM MISC.RECORD

1. BED LIGHTED AT A TOTAL BED COKE K
(2+3+4) g
2. Bed coke 40%( Kg) at B Coke bed height Inc
h
3. Bed coke 30%( Kg) at C Total Blast on(8-6) Hrs
Min
4. Bed Coke 30%( Kg) at D Down time(If any) Hrs
Min

5. Charging Started at E Total No, of charges N

os
6. Blast on at F Total tons melted
T
7. Metal at spout G Tonnes melted /hour T
F/(C-D) /Hr
8. Blast off at I Coke:Metal Ratio

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COMPARISON OF PARAMETERS WITH OPTIMUM (AS
STANDARDISED)
Sr Parameter Optimum Actual
No.
I Bed Preparation Time

II Bed Height

III Bed Weight

IV Weight of metal charge

V Weight of coke charge

VI Melting rate

VI Blast volume upper

VII Blast volume Lower

VIII Blast Pressure upper

IX Blast pressure lower

Process Failure Factors

1. Fabrication: Structure, Material, dimension, quality of valves, workmanship,

leakages

44
2. Equipment: installation, working, specifications, installation of blower,

support to blower platform

3. Instrumentation: Amp, voltmeter, Carbon-Silicon meter, Temp. gauge,

Pressure and volume meter

4. Power Failure: voltage, power,

5. Operational error: preparation of spout, preheating, lining, repairing,

charging, bed preparation

6. Raw Material: Composition, Size weight of scrap

7. Fuel: Quantity, weight

45