Castings: Cupola Furnace Fundamentals

The Cupola Furnace Fundamentals course provides learners a comprehensive overview of the basic elements of a cupola. Using graphics and animations, users are able to learn more about the functions of the main furnace components, as well as the cupola’s ancillary systems and assistive devices. The course also discusses the different instrumentation, fuels, and charge materials that may be used to operate the cupola.


Learning Objectives

  • Identify all of the components of a cupola furnace system and discuss their functions.
  • Understand how each element of the cupola works together during an operation.
  • Distinguish between the cupola fuels.
  • Recognize how the different cupola fuels affect the melting process.
  • Differentiate between the three main categories of charge materials.
  • Demonstrate an understanding of why the charge materials are added.
Course Length: 6 HRS

Table of Contents

Parts of the Cupola

  • Cap
  • Charge Opening
  • Shell
  • Windbox
  • Tuyeres
  • Well
  • Molten Metal and Slag Exit Holes
  • Cupola Bottom
  • Bottom Doors
  • Legs

Primary Fuels

  • Foundry Coke
    • Size
    • Strength
    • Chemistry
    • Moisture
  • Air
    • Moisture
    • Temperature
  • Formed Coke

Ancillary Systems

  • Exhaust System
    • After-Burner
    • Recuperative System
    • Quencher
    • Bag House
    • Wet Collector or Scrubber
  • Charge Weighing System
    • Magnet Crane
    • Weigh Hopper with Digital Display
    • Charge Bucket, Skip, or Skip Hoist
    • Charge Feeder
  • Blast Air System
    • Blower
    • Blast Piping
  • Molten Metal Handling System
    • Trough
    • Slag Skimmer
    • Iron Dam
    • Fixed Volume Holding Vessels

Charge Materials

  • Charge Metallics
    • Size
    • Chemical Composition
    • Appearance
  • Fluxes
    • Amount
    • Primary Fluxes
    • Secondary Fluxes
  • Alloy Materials
    • Analysis
    • Size
    • Weighing
    • Melt Losses
    • Silicon Carbide

Assistive Devices and Instrumentation

  • Refractory Installation Tools
    • Lining Gun
    • Ram
  • Cleaning and Removal Tools
    • Bottom Dropping Devices
    • Chipping Tools
  • Safety Devices
    • Pop-Offs
    • Safety Tuyere
  • Measuring Instrumentation
    • Blast Rate Controller
    • Molten Iron Spout Temperature Display
    • Immersion Thermocouple
    • Blast Air Temperature Display
    • Internal Pressure Gauge
    • Water Flow Rate Gauges and Water Temperature Displays

Secondary Fuels

  • Anthracite Coal
  • Oxygen Enrichment Process
  • Injected Fuels
  • Oxy-Fuel Burners

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