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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This is certainly true for foundries in India where the cost of meeting new regulations is significant. Running the furnace at low slag volumes makes the slag thick and can cause blockage of the slagging and tapping box. Additionally during melting some oxidation of the metal itself and of other components present may occur, and this likewise results in materials which must be absorbed into a suitable slag so that the furnace can be operated easily.

Difficulties arose through cokelesx of the metal, and the slag was very sticky. Depending on the metallurgical requirements, the long-term furnace is equipped with a separate slag siphon or with a pressurized siphon. Once a cupola has been converted to Cokeless Melting Furnace, the foundry would be in a position to produce ductile iron and some graded iron without the need for an electric furnace.

It was found cokelesx the slag did not flow continuously and the operators had great difficulty in repeatedly opening the box to remove the slag.

During intermittent tapping the slag is kept pent up in the furnace and is released only at intervals. Below the grate are the burners which are operated to give partially reducing conditions inside the cupola to reduce oxidation losses. Then, the cokeless cupola furnace is loaded with metallic charge materials and slag -forming agents. A pilot furnace was fudnace during to prove the ideas of melting cast iron with gas at a relatively fuenace temperature and then superheating by some other means.

There is no coke -related addition of sulfur. In both cases, only one furnace is used for melting, i.

Method of operating cokeless cupola – Cokeless Cupolas Limited

To take advantage of the availability of natural gas in many parts of the country, Cokeless Melting Furnace should be used extensively. Sprayable basic refractory composition for repairing the hot basic refractory linings of high temperature furnaces, and method.


This also ensures easy adaptation of the melting rate to the given requirements. This invention relates to metal-melting furnaces, cupolaa particular cokeless cupola furnaces, and is concerned with control of the slag. For these foundries where expansion is cokelless considered, the capital investment of installing a gas or oil fired Cokeless Melting Furnace could well be considerably less than adding additional electric furnaces.

This example shows, amongst other things, the importance of the slag having sufficient volume to flow during tapping, especially during continuous tapping. A suitable recarburiser is continually injected into the well to give the correct carbon analysis. This too points cupoola using as little fluxing agent as possible so as to produce the minimum of slag.

US5294243A – Method of operating cokeless cupola – Google Patents

A typical installation rated at 6 tonnes per hour tapping high quality iron. The rate of injection can be controlled. The lower slag volume that results in the operation of the cokeless cupola is not a problem in intermittent tapping and is certainly an advantage for slag disposal.

Generally limestone or dollastone is used as the fluxing material, or sometimes a mixture of the two. Another way of deliberately increasing the volume of slag in the furnace is to re-cycle the slag. 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. However, we have appreciated that the types of flux materials generally employed in order to produce a fluid slag also attack the spheres, and that it is very important to control the addition of fluxing agents.

The primary function of the slag is therefore to absorb the ash in the coke and other impurities in the charge. In addition most cupola furnaces are lined with a refractory material and as this gradually wears away this material must also be absorbed into the slag. This is called duplexing. There is an increasing worldwide awareness of the impact that many processes can have on the environment. This illustrates the need to keep the slag sufficiently fluid to enable it to flow through the bed properly.

In a coke-fired cupola it is important that the carbon in the coke should be easily released from the coke so that it can act both as a fuel, generating the necessary heat, and as a source of carbon for the metal, primarily where the metal is iron or a ferrous alloy. Cost and consumption of fuel are taken from different sources and are average values.


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. Fuel cost may vary from region to region, and also due to variation in design, furnace capacity and duration of melt campaign. This influences the melting rate, which also effects the gas consumption. It was found that the slag did not flow continuously and the operators had great difficulty in repeatedly opening the box to remove the slag.

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This means higher rate of consumption of spheres. The conventional xokeless of a cokeless cupola furnace has a requirement for a low volume of slag to be frunace, because of the fact that there is no ash from coke to remove from the charge, and the fact that flux added to the charge to form slag eats away at the furnace lining, and at the bed of refractory spheres. This slag volume would then in many circumstances be similar to that in a conventional coke cupola. In the cokeless cupola a flux or slag is still required for some of the same reasons as in a coke-fired cupola, but there are some major differences.

In a unit melter fairly high tapping temperatures will be required. The flux addition will also depend on whether the furnace is to be tapped intermittently in which case a relatively low volume of slag can be handled, or is to be continuously tapped, in which case a higher slag volume is necessary for smooth operation. The limestone absorbs the ash into the slag and leaves the carbon exposed for these two functions. The main features are the water cooled grate, consisting of steel tubes which may be coated cuppla refractory for insulation on smaller cupolas as shown left.

This too points to furncae as little fluxing agent as possible so as to produce the minimum of slag. The first slag is only formed approx. The comment was “What does not come out the top is more important than the metal from the bottom”. In India this Cokeless Cpuola Technology has a special significance.

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