DESIGN AND FABRICATIONOF CUPOLA FURNACE

Abstract

A 650 kilogram capacity cupola furnace was fabricated from locally available materials for the production of cast iron using pig iron, contaminated steel scraps, foundry returns and fluxes. The main fuel used is metallurgical coke. After analyzing the design parameters, the shells were fabricated in four segments for easy lining: the stack zone, preheating zone, combustion zone and the hearth. Mild steel sheet of 4 mm thickness was procured, marked out as per the drawing, sliced and rolled into cylindrical shapes and the joints welded continuously. The internal configuration was lined first with asbestos paper measuring 4 mm thick using water-glass to enable it adhere to the internal shell of the segments, thereafter, a less dense insulating refractory material was used and finally fire clay refractory bricks was used for lining since it interfaces directly with the molten metal. The various segments were then assembled and erected with the blower connected to the combustion zone. This report also contains the materials and components bill.