Cupola Furnace Operations

Table of Contents

1. The Cupola Process
   1. The Melting Process in the Cupola Zones
      1. Preheating Zone
      2. Melting Zone
      3. Reduction Zones
      4. Oxidation or Combustion Zone
      5. Well Zone
   2. Heat Transfer
   3. Chemical Reactions
   4. Gas Reactions in the Oxidation Zone
2. Cupola Turnaround
   1. Heat Turnaround
   2. Campaign Turnaround
      1. Draining the Trough
      2. Quenching the Cupola
      3. Dropping the Cupola Bottom
      4. Chipping and Patching the Cupola
      5. Making the Cupola Bottom
      6. Preparing the Coke Bed
         1. Igniting the Coke Bed
         2. Measuring the Coke Bed
3. Operating Procedures
   1. Cupola Procedures
      1. Preparation
         1. Equipment Checks
         2. Purchased Material
         3. Construction
         4. Coke Bed
         5. Cupola Patching
         6. Cupola Bottom
      2. Fill-Up
      3. Start of Melt
      4. Operating
      5. Shutdown
   2. Melting Records
      1. Raw Material Log
      2. Daily Charge Calculation
      3. Cupola Log
4. Control Tests
   1. Metal Tests
      1. Temperature Measurement
      2. Cooling Curve Analysis
         1. Sampling
         2. Pouring a Cooling Curve Sample
      3. Chill and Wedge Tests
         1. Sample Type
         2. Sample Size
         3. Sampling
         4. Pouring a Chill or Wedge Sample
      4. Chemical Analysis (Metal)
   2. Slag Tests
      1. Slag Appearance
         1. Sampling
         2. Evaluation
      2. Chemical Analysis (Slag)