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FURNACES
6.1 Introduction
The energy use analysis was performed on some melting furnaces. It is found
influenced by electrical efficiency and thermal loss. This thermal loss results in
and efficiency in induction furnaces. This chapter also deals with cupola
Composition and control depend on charging the metal of known analysis and
formulates charge model, which offers a rapid and simple solution to the
problem.
consumption. The factors influencing the energy use are furnace capacity,
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6.2.1 Effect of furnace capacity
temperatures varies according to the thermal properties, analysis and the final
temperature of the metal. It normally ranges between 370 kWh/ton and 390
kWh/ton of different iron grades [87], This value is useful in determining the
their efficiency. Thermal efficiency can be calculated using the equation 2.3
and the results are shown in Table 6.1. The theoretical energy estimated for
Table 6.1 reveals that the energy consumption is decreases with the
increases.
The thermal loss varies according to the size, specific power level and time of
[91] are conductive losses through lining, heat losses associated with slag
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and radiation losses when the furnace lid is open. Due to high thermal losses,
where TL: Thermal loss, AE: Actual energy used / ton during the furnace
efficiency for furnace, transformer and capacitor system, Tm: Total production
tons
and this is shown in Figure 6.1. It is observed that the size of the furnace and
production rate are the factors influencing thermal loss. Further, the
conduction loss and radiation loss for 750kW furnace at the tapping
However, the required tapping temperature for gray cast iron should be
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Thermal loss (kW)
CM
co
Capacity(tons)
loss factor and the lining thickness. In many furnaces thick refractory lining is
used to reduce heat losses and this provides adequate protection against
metal break out. It is observed in the study that while thicker lining reduces
The refractory lining erodes away during its operational life as it becomes
thinner and thinner. Due to this, induction coil draws higher power with
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consumption. Table 6.2 illustrates the life of lining in 3.5-ton induction furnace
Some of the important factors affect energy efficiency are carbon pickup by
small and medium scale foundries follow the rule of thumb or best guess. The
are alternative combinations of raw materials for a given heat and the
foundrymen were not able to compare the various alternatives. Also when
one’s experience is relied on, often some inefficient method can be repeated
over and over again. This causes variations in melting temperature, analysis,
The charge calculation is given here as the charge mix specifying a target
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performance. This will ensure that the proper composition is obtained for all
heats produced.
it by the total weight of the charge determine the average content of each
conditions and this is illustrated in Figure 6.2. The model on cupola charging
to be obtained.
spout composition.
The Values of aggregate charge were calculated using the equations given
below
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n,m
ac- ^(Wjxc^nooo
7=1,*=1
(6.1)
n,m
ASi = £(W5fx&*)/1000 (6.2)
7=1,*=1
n,m
AMn = £(^xM?A;)/1000 (6.3)
y=l,*=1
nym
AP = ^(WjxPk)/1000 (6.4)
7=1,*=1
n,m
AS = J^iWjxSk)/1000 (6.5)
j=i,*=i
Loss or gain of a metal and its constituents is calculated using the following
equations.
LCO=(AC+L1) (6.6)
LSiO=(ASi*L2) (6.7)
LmnO=(AMn*L3) (6.8)
LSO=(AS+L5) (6.10)
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The adjustment value of silicon = Diff* 12.24 (6.16)
manganese and sulphur is found out at spout (molten metal). The values of
and they are modified to account for the value of K .This is given as
K=0.00451T-4.30 (6.19a)
T=(K+4.30)/0.00451 (6.19b)
where AC: Amount of total carbon in charge%, ASi: Amount of total silicon in
Weight of the metals of j th metal, Ck, Sik, Mnk, Pk, Sk: k th constituents
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Start
u
Enter loss or gain during melting from
the previous records
--------------------- 3-------------------
Print Estimated analysis
sx
-IJ~
End
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6.3.3 Case study
manufactures mainly grey cast iron castings. The basic inputs required for the
furnace are coke, pig iron and foundry returns. Many foundries have different
returns. Some of the important parameters identified for the melting operation
material as shown in Table 6.3. The data of average loss or gain in the
L1 L2 L3 L4 L5
(carbon (Silicon (Manganese Phosphorous loss %) (Sulphur loss
loss or gain loss in %) loss or gain or gain %)
in %) %)
15% gain 10-20% 25 % loss No loss or gain 5% gain
loss
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Table 6.5 Material usage
Day Pig iron Return (kg) Cl Scrap (Kg) Coke (kg) Ferreisilico
n kg)
Kg % wt Kg % wt kg % wt kg % wt of kg % Wt
(Wj) of (Wj) of (Wj) of (Wj) charge (Wj) of
charg charge charge char
e -ge
1 291 29.05 417 41.76 292 29.17 171 17.1 4 0.4
2 291 29.12 419 41.87 290 29.00 175 17.5 4 0.4
3 327 32.70 345 34.47 328 32.87 171 17.1 4 0.4
4 327 32.70 345 34.47 328 32.87 171 17.1 4 0.4
5 328 32.77 347 34.70 325 32.50 177 17.7 3 0.30
6 303 30.34 407 40.68 290 29.00 169 16.9 4.4 0.44
7 290 28.97 343 34.27 367 36.75 168 16.8 1.9 0.19
8 266 26.58 354 35.36 380 38.04 171 17.1 3.14 0.31
9 221 22.14 421 42.14 358 35.71 182 18.2 1.5 0.15
10 193 19.30 414 41.37 393 39.30 168 16.8 2 0.20
11 217 21.66 417 41.67 366 36.66 169 16.9 1.4 0.14
12 260 26.07 361 36.13 379 37.80 162 16.2 3.8 0.38
13 217 21.70 418 41.80 365 36.50 171 17.1 2.2 0.22
14 234 23.40 438 43.80 328 32.80 160 16.0 3 0.30
15 208 20.78 466 46.63 326 32.50 163 16.3 2.5 0.25
16 214 21.35 414 41.35 372 37.28 168 16.8 2.3 0.23
17 223 22.30 423 42.30 354 35.38 189 18.9 3.2 0.32
18 201 20.10 519 51.90 280 28.01 154 15.4 1 0.10
19 181 18.13 488 48.80 331 33.06 160 16.0 1.2 0.12
20 208 20.85 327 32.73 465 46.41 181 18.1 1.3 0.13
21 216 21.64 398 39.77 386 38.58 168 16.8 1.2 0.12
22 287 28.66 336 33.55 377 37.77 176 17.6 2 0.20
23 253 25.29 379 37.94 368 36.75 183 18.3 2 0.20
24 326 32.58 303 30.34 371 37.07 175 17.5 2 0.20
It was observed from Table 6.5 that the large variation in coke
The cupola furnace burns coke with an air blast to melt scrap, cast iron and
alloying materials into consistent grade iron for casting purpose. The random
output. Controlling this phenomenon is desirable for efficient energy use to get
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Table 6.6 Charge mixing variation of existing practice and the resultant
cupola output composition
Day Carbon at Silicon % at Tapping temperature UC Phosphorous
spout spout % at spout
1(10%) 2(20%) 1 2
1 3.46 1.72 1.91 1457 1470 0.193
2 3.46 1.73 1.92 1458 1470 0.193
3 3.45 1.73 1.92 1459 1469 0.205
4 3.45 1.73 1.92 1459 1469 0.205
5 3.45 1.73 1.92 1459 1469 0.197
6 3.46 1.74 1.93 1460 1471 0.194
7 3.43 1.71 1.89 1455 1465 0.193
8 3.42 1.70 1.89 1454 1464 0.193
9 3.42 1.69 1.88 1452 1462 0.205
10 3.41 1.68 1.86 1450 1460 0.205
11 3.42 1.69 1.88 1452 1462 0.197
12 3.42 1.70 1.89 1453 1477 0.194
13 3.42 1.69 1.88 1452 1462 0.193
14 3.55 1.70 1.89 1467 1477 0.168
15 3.59 1.69 1.88 1470 1480 0.172
16 3.52 1.68 1.86 1462 1472 0.163
17 3.54 1.69 1.88 1464 1474 0.166
18 3.55 1.69 1.88 1465 1475 0.172
19 3.54 1.67 1.85 1464 1474 0.172
20 3.48 1.67 1.85 1457 1467 0.172
21 3.54 1.67 1.85 1464 1474 0.171
22 3.57 1.71 1.89 1471 1481 0.193
23 3.55 1.69 1.88 1465 1475 0.166
24 3.59 1.72 1.91 1475 1485 0.205
The charge mixing variation from the existing practice and the resultant
charge metal is the major input variable influencing the tapped metal
composition.
The factors affecting cupola furnaces are percentages of carbon and silicon.
The details of these factors are given in this chapter. The carbon and silicon
study is given in Figures 6.3 and 6.4. It is observed that around 1460°C there
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is a sudden increase in the percentage of carbon and silicon (oxidation) due
Temperature in C at spout
Tapping Temperature 0 C
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This study helps to monitor and control a wide range of foundry
process variables and material properties efficiently. It was observed from the
case study that changes in the levels of carbon and silicon are related to
tapping temperature and also the spout temperature influences the casting
The principal objective of cupola control should be to ensure that the metal of
used to relate each cupola variables, for example, metal temperature and
metal composition. Having calculated the composition of the base iron at the
cupola spout, the multiple regression model predicts the temperature based
In this work the SPSS software is used for statistical analysis and following
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where T: Temperature °C, C: Carbon, Si: Silicon P: Phosphorous
provided the value of the parameters lies within the concerned ranges.
using the data is 0.942 or 94.95 % and the factors like carbon, silicon and
The analysis of variance and statistical analysis are summarised in Tables 6.5
and 6.6 and they show that the relationship between the temperature and the
the best fit. An analysis of residuals is a powerful tool to confirm the nature of
relationship.
Total 9 915.600
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Table 6.8 Summary of statistical analysis
important that furnaces of small and medium capacity should be operated with
high utilisation factor. The operations of cold blast cupola can be represented
regression analysis. The model helps to obtain the metal temperature from
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of the metal charged. It is observed from this study that the production of
liquid iron with closely controlled composition^, Mn, Si, S) is the major
for the desired output with the least energy consumption is very difficult. So in
this study an attempt has been made to improve the cupola charging system
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