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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In order to furnac uniform melting conditions, the furnace is equipped with state-of-the-art gas burners. Process of blowing high-oxygen gases into a molten bath which contains non-ferrous metals. A special compensating siphon is used to adjust the slag bath height according to the desired carburizationmaking it possible to change the dripping zone in the cupola seen from the siphon. Duplexing A Cokeless Melting Furnace is a very efficient melting unit as furjace material is added to the top; the metal is preheated as it moves down the shaft and after melting is superheated as it passes through the bed.

Reduced bed height reduces the tapping temperature but increases the melting rate. Simpler more manual systems are also manufactured. Some examples will now be described to illustrate what can happen when a cokeless cupola is not run in accordance with the invention.

For coke cupola, both price and consumption rate of coke will vary significantly depending on ash content.

Firnace the same time, flux is still necessary to absorb the material originating from wear of the furnace lining and whilst in some cases a similar lining is used and the action is therefore similar, the actual lining consumption is much less, so here again there is a difference resulting in a lower need for a flux. Absence of sulphur makes the molten metal obtained from Cokeless Melting furnace suitable for conversion, after superheating, into Ductile Iron without going through the de-sulphurision process where temperature is reduced due to endothermic reaction.

A method according to claim 1 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. A method according to claim 16 cokelses the silica comprises broken bottles, jars, gravel. This too points to using as little fluxing agent as possible so as to produce the minimum of slag.


This means a considerable improvement over cold-blast operation. It is very difficult to take an analysis of the composition of the slag above the bed so the operator has to rely on the analysis of the slag after it has been removed from the furnace and after making certain assumptions regarding the amount of sand and dirt in the charge, as well as with regard to lining wear and rate of consumption of the spheres.

A method according to claim 6 wherein the silica comprises broken bottles, jars, gravel. During this process, the counter flow principle is used to transfer heat from the combustion gases to the charge until it is melted Figs.

On the other hand, although we propose to add more fluxing material than is conventional, if too much fluxing material is added, with a view to keeping the slag fluid, the spheres will be attacked by the fluxing materials, leading to a high consumption of spheres which not only increases the operating cost but also, because of the reduced thickness of the bed as the spheres are consumed, leads to problems of insufficient superheating of the metal and consequently low tapping temperatures.

In both cases when the slag flows it is sufficiently fluid to flow easily. A method according to claim 11 wherein silica is added to the charge as a fluxing agent. The hot flue gas from the natural-gas-fired burners flows through and superheats the layer of ceramic spheres and ensures that the charge column is thoroughly preheated.

However, with the injection process used in the Cokeless Melting Furnace, this does not present a problem. Critical aspects of cokeless melting are often considered to be the slag flow due to the low temperature level in the shaft section and the lack of carburization along with the associated difficulties when using high scrap steel volumes.

Advantages of the liningless furnace include a reduced lining effort and the somewhat longer furnace campaign, while long-term furnaces with a lining provide the benefit of lower heat losses, ultimately resulting in reduced coke consumption and better energy utilization associated with the above-mentioned benefits for the environment and the climate.

The primary function of the slag is therefore to absorb the ash in the coke and other impurities fudnace the charge.

USA – Method of operating cokeless cupola – Google Patents

Therefore melting iron in cupola at low temperature and superheating in an electric furnace is a very cost effective combination. We have discovered that slag control is essential to the correct operation of a cokeless cupola as opposed to being of minor importance as was previously felt. The investment costs are low compared to other units. During intermittent tapping the slag is kept pent up in the furnace cokelesd is released only at intervals.


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This influences the melting rate, which also effects the gas consumption. Sprayable basic refractory composition for repairing the hot basic refractory linings of high temperature furnaces, and method.

Furnacf, compared with a unit melter, the overall gas consumption also reduces. EXAMPLE II A cokeless cupola operating with a clean charge and with what were mistakenly thought to be correct proportions in the charge including 12 Kg of dollastone per charge was found to exhibit very rapid consumption of the spheres, with the consequence that the bed almost vanished by the end of an eight-hour shift, resulting in insufficient superheating and low metal temperature.

EXAMPLE II A cupolw cupola operating with a clean charge and with what were mistakenly thought to be correct proportions in the charge including 12 Kg of dollastone per charge was found to exhibit very rapid consumption of the spheres, with the consequence that the bed almost vanished by the end of an eight-hour shift, resulting in insufficient superheating and low metal temperature.

Moreover, cheap scrap steel can hardly be used and relatively wide tolerances must be applied in order to ensure accurate analyses of the spout iron. The examples show the importance of slag control.

An automatic control system forms part of the main control panel and the air and fuel flows to each burner are also monitored. The heat in the counter flow is transferred to the top-fed material. The metal is pre-heated in the upper part of the furnace and melts just above the spheres; it is then superheated as it trickles down over the spheres.

Method of operating cokeless cupola – Cokeless Cupolas Limited

Pig iron Foundry pig iron Furnace clogging. The oxidation losses are lower than in a coke-fired furnaces so again, from this aspect, less flux is required. A carbon injection unit, therefore, will be required which continually blows carbon into the cupola during melting.