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DESIGN AND MODELLING OF CUPOLA
DONE BY
CEASE JUNIORFIJO GEORGE
FOUZIYA C M
HAREESH MOHANAN
JESBIN JOSE
JIBIN JOSEPH
DEPARTMENT OF PRODUCTION ENGINEERING
VIDYA ACADEMY OF SCIENCE & TECHNOLOGY
THALAKKOTTUKARA, THRISSUR- 680 501
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CONTENTS
• OBJECTIVE OF PROJECT
• INTRODUCTION
• CONSTRUCTION
• CUPOLA OPERATIONS• ADVANTAGES AND LIMITATIONS
• DESIGN CONSIDERATIONS
• DESIGN
• FABRICATION DETAILS• BIBLIOGRAPHY
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OBJECTIVE OF PROJECT
• TO DESIGN AND FABRICATE A MODEL
OF SIZE 2 CUPOLA IN THE RATIO 1:2
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FURNACES
• FURNACES ARE OF TWO TYPES• 1. BLAST FURNACES
• 2. FOUNDRY FURNACES
• Blast furnaces performs basic melting operations i.e.
melting of metal ores.
• Foundry furnaces are used to casting purposes.
• Heat in a remelting furnace is created by• 1. Combustion of fuel
• 2. Electric arc
• 3. Electric resistance
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HISTORY OF CUPOLA
• DEVELOPMENT OF BLASTFURNACE FOR THEREDUCTION OF IRON OREGAVE BIRTH TO IRONFOUNDING
• AS TIME WENT ON REMELTINGOF PIG IRON FOR MAKINGGRAY IRON CASTINGS - WHICHLEAD TO THE EVOLUTION OFCUPOLA
• CUPOLA PLAYED A MAJORROLE IN THE INDUSTRIAL
REVOLUTION• FIG SHOWS STATITICS OF
FURNACES IN THE PERIOD1962-63 IN U.S AND CANADA
0
500
1000
1500
2000
2500
3000
CUPOLA
ELECTRIC ARC
INDUCTION
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CONSTRUCTIONAL FEATURES
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CUPOLA OPERATIONS
• PREPARATION OF CUPOLA
• LIGHTING THE FIRE IN THE COKE BED
• CHARGING OF CUPOLA• MELTING
• SLAGGING AND METAL TAPPING
• DROPPING DOWN THE BOTTOM
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PREPARATION OF CUPOLA
• The bottom door is dropped down and
cleaned
• Damaged firebricks are replaced
• Repairing and patching of refractory lining
• Ramming of sand bed
• Drop door is closed ,when the furnace isreconditioned
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LIGHTING THE FIRE IN THE COKE BED
• Cupola is started 3hr before the molten
metal is to be poured
• Soft and dry pieces of wood is placed over
the sand bed
• Coke is placed over the wooden pieces
• Air enters through the tuyeres• Electric spark igniters and gas torches are
also used for ignition
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CHARGING OF CUPOLA
• Charged from the charge door
• Alternate layers of Limestone (flux), Iorn,
Coke (fuel) up to charge door
• Sodium carbonate ,calcium carbide etc
also used as flux
• A metal charge would have pig iron, scrapiron, returns etc
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MELTING
• Soaking period of 30-60 minutes to
preheat
• Blast is turned on
• Molten metal accumulated at bottom
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SLAGGING AND METAL TAPPING
• Slag hole is opened, slag spouted is
collected in a container
• As air blast continues, melting progresses
and the molten iron is tapped for pouring
into the molds
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DROPPING DOWN THE BOTTOM
• All the contents are allowed to melt till one
or two charges are left above the coke bed
• Blast is shut off, the drop door is opened
and remains in the cupola is removed
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ZONES
• WELL
• COMBUSTION ZONE
• REDUCING ZONE• MELTING ZONE
• PREHEATING ZONE
• STACK ZONE
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COMBUSTION ZONE
15-30 cm above the tuyeres
1550-1850 0c
C+O2
CO2+heat2Mn+o2Mno2+heat
Si+O2SiO2+heat
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REDUCTION ZONE
• Top of combustion zone to the top of the
coke bed
• CO2+C2CO-Heat
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MELTING ZONE
It starts from first layer of metal charge to a
ht of 90 cm
3Fe+2CO
Fe3C+CO21600c
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PREHEATING ZONE
• From Melting zone to the bottom of
charging of the charge door
• 1100c
Stack zone
From preheating zone to the cupola shell
ends.• Hot gases passes escape through the
stack
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ADVANTAGES
• SIMPLE DESIGN AND EASIER CONSTUCTION
• LOW COST OF MELTING
• SIMPLE TO OPERATE AND MAINTAIN IN GOODCONDITION
• ECONOMY IN OPERATION AND MAINTANENCE
• LESS FLOOR REQUIREMENTS
• COULD BE CONTINOIUSLY MELTED
• ADEQUATE TEMPERTURE CONTROL
• CHEMICAL COMPOSITION CONTROL
• EFFICIENCY OF CUPOLA VARIES FROM 30 TO 50%.
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LIMITATIONS
• SINCE MOLTEN IRON AND COKE ARE
IN CONTACT WITH EACH OTHER,
CERTAIN ELEMENTS LIKE Si, Mn ARE
LOST AND OTHERS LIKE SULPHUR ARE PICKED UP. THIS CHANGES THE
FINAL ANALYSIS OF MOLTEN METAL.
• CLOSE TEMPERATURE CONTROL ISDIFFICULT TO MAINTAIN
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DESIGN CONSIDERATIONS
• COST EFFECTIVE
• PORTABILITY
• EASY TO HANDLE• ABLE TO EXPLAIN THE WORKING
CONDITIONS
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DESIGN
• USING THE DESIGN CONSIDERATIONS
WE ARE AIMING TO DESIGN AND
FABRICATE THE CUPOLA OF SIZE 2 IN
THE RATIO 1:2.
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CUPOLA SIZE 2 REDUCEDDIMENSIONS
SHELL DIAMETER 36” 18”
DIAMETER INSIDE LINING 27” 13.5”
MELTING RATE TONNES/HR (IRON TO
COKE RATIO 10:1)2.75 1.375
BED COKE HEIGHT ABOVE TUYERES
(in)
36-42” 18”
COKE AND IRON CHARGES (lbs) 45 & 450 22.5 & 225
FLUX (lbs) 9 4.5
Cfm AIR THROUGH TUYERES 1290 645WIND BOX PRESSURE (oz) 12 6
TOTAL AREA OF TUYERES (sq”) 118 60
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Height of the cupola 210cm
Length of the wind box 30cm
Height of the wind box from thesand bottom
30cm
No: of tuyeres 6
Wind box dia 60cmSlag hole height 20cm
Tap hole height 8cm
Charging door area 20*20=400cm2Charging door height 120cm
Charging platform height 160cm
Base platform length 60cm
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FABRICATION DETAILS
• MATERIALS REQUIRED – QTY OF GI SHEET 5 sq.metres
– QTY OF 8mm dia iron rod 21 metres
– OTY of ¾” hollow pipe 6.5 metres
– QTY of 25*25*6 angle iron 1 metre
– QTY of 6*3 ms flat 10 metres
– QTY of 50*8 ms rectangular pipe 4 metres
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MODELLING DETAILS
• First of all, we have constructed the
structure or the base to be which the
sheets have to be rolled and the legs.
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• After the construction of the base we have
gas welded the sheets, tuyeres, wind box,
spark arrester
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• Then we coated primer to it. And the
charging platform is done with the ladder.
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• Then we fabricated the inside surface of
the cupola and the painting is done.
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BIBLIOGRAPHY
• PHILIP C ROSENTHAL. RICHARD W
HEINE, CARL R LOPER, “PRINCIPLES
OF METAL CASTING”, TATA McGraw –
HILL EDITION
• Dr. O P KHANNA, “FOUNDRY
TECHNOLOGY”, DHANPAT RAI
PUBLICATIONS.
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