Autotherm Equipments Corporation is well known manufacturer,exporter and supplier of Cokeless Cupola Furnaces at market leading price from Coimbatore,, . EcoMelt Cokeless Melting Furnace is a Vertical Shaft Melting furnace and was as a melting unit for Cast iron without use of coke as in a conventional cupola. The development of the cokeless cupola began in the United Kingdom at the foundry of Hayes Shell Cast Limited in the mid s. A pilot furnace was built.

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A method according to claim 2 wherein limestone, dollastone is added to the re-cycled slag as another component of the fluxing agents. This slag volume would then in many circumstances be similar to that in a conventional coke cupola. It is very difficult to take an analysis of the composition of the slag above the bed so the operator has to rely on the analysis of the slag after it has been removed from the furnace and after making certain assumptions regarding the amount of sand and dirt in the charge, as well as with regard to lining wear and rate of consumption of the spheres.

There is no ash to flux, so one of the main reasons for adding a flux has been eliminated. In this case high-alumina linings are often employed and this alumina has to be absorbed into the slag as the lining wears.

US5294243A – Method of operating cokeless cupola – Google Patents

However there is still dirt in the charge and sand sticking to the returns, and so these materials still have to be converted into a fluid slag.

In addition to the savings below, there are substantial savings for an EcoMelt Cokeless Melting Furnace compared to a coke cupola as there is almost no need for pollution control equipment. Immediately the slag flowed with good fluidity and the bridging problem disappeared.

If insufficient fluxing agents are added, the result is a slag which is viscous rather than fluid, cupolx it does not flow easily through the spheres. This normally results in excessive consumption of the heat-exchange bodies. Pig iron Foundry pig iron Furnace clogging. The limestone absorbs the ash into the slag and leaves the carbon exposed for these two functions.


Cokeless Cupola Furnaces Manufacturer,Cokeless Cupola Furnaces Exporter,Supplier in Coimbatore

The most important aspect which highlights the invention comeless the use of refractory spheres in the cokeless cupola, as described in our British Patent Specification No. The Cokeless Melting Furnace is cokelless with partially reducing conditions.

Pig iron Foundry pig iron Furnace clogging Literature: Particular benefits include a guaranteed reliable production process with only little spread in iron composition. The Gas fired Cokeless Melting Furnace for Iron melting was developed over 30 years ago and a comment passed about its performance in the early days is still very appropriate and probably more relevant, particularly in view of today’s stringent pollution norms.

A method according to claim 11 which further comprises the step of re-cycling slag removed from the furnace by re-introducing at least a portion of the slag as a component of the slag-forming fluxing agents. Either way, the dripping zone in the furnace is independent of any fluctuations in pressure. A pilot furnace was built during to prove the ideas of melting cast iron with gas at a relatively low temperature and then superheating by some other means. It was patented by him in the year If more limestone were to be added in a cokeless cupola to maintain fluidity it would increase greatly the rate of consumption of the spheres, increasing the overall running costs as well as furnave the length of melting run that is possible.

A method according to claim 6 wherein the silica comprises broken bottles, jars, gravel. Then, CO 2 is partly reduced again, consuming energy and cokeand the combustion product carbon dioxide and the supplied coke are present in a reaction equilibrium with carbon monoxide eq.

This is called duplexing. This also ensures easy adaptation of the melting rate to the given requirements. In a cokeless cupola lined with a high alumina material, and operated for one week without repair although melting on only a single shift, the quantity of dollastone added to take care of the dirt, and the products of wear on the spheres and the wear on the lining was of the order of 2 to 2.

The melting point of the slag was barely higher than the tapping temperature and so with a small stream of slag the stream tended freeze off altogether and had to be re-started.


However, such a mode of operation is only reasonable for at least two-shift operation, the furnace being interrupted see Interruption in the meantime. The depth of the bed of spheres governs the amount of superheat and therefore the tapping temperature.

Thus, the required energy is generated in the cupola itself, i. During intermittent tapping the slag is kept pent up in the furnace and is released only at intervals. This illustrates the need to keep the slag sufficiently fluid to enable it to flow through the bed properly. This control may involve deliberately increasing the volume of slag by suitable additions in order to operate a continuously tapped furnace smoothly.

In a unit melter fairly high tapping temperatures will be required. If the operators failed to clear the slag box at regular intervals the slag built up within the furnace to a point where it approached the area of the burners and was agitated into a foam which could rapidly increase in height and block the burners. This makes maintenance easier and more economic. A typical slag analysis would have a composition in the following range: Tapping temperature has the main influence on economics, which as described above depends mainly on bed height.

The invention adds more flux materials than is conventional, preferably including silica in the form of broken bottles, so as to deliberately increase the volume of slag, improving the flow.

The examples show the importance of slag control. Therefore, compared with a unit melter, the overall gas consumption also reduces. This can reach the point where, in a bad condition, the slag can be blown back up the furnace shaft, causing severe operational difficulties and in the worst case the melting of the metal ceases altogether as the metallic charge becomes coated with the viscous slag. The foundry industry in India is rapidly expanding and many foundries have adopted electric melting, particularly for the production of ductile iron.

Moreover, in a cokeless cupola slag control is much more fupola because of the lower temperatures.