Cokeless Cupola Furnaces from Dueker

ENGINEERING
Cokeless Cupola Furnaces
Economical and environmentally melting plants
Development · Planning · Realization
Cokeless cupola furnaces from Düker – over 500 years of experience in iron casting
The name Düker has stood for top quality iron casting for more than 500 years. Today we are one of
the leading manufacturers of fittings, pressure
pipe fittings for drinking water and gas supplies
and of pipes and fittings for drainage technology.
We also manufacture highly resistant enamelled
components and pipes for the chemical and
pharmaceutical industries. Another production field
of our business is job castings where we act
as a contract manufacturer for parts for the
printing, automotive and mechanical engineering
industries.
Our own cokeless cupola at our plant in Karlstadt
Consultancy
Düker Engineering – worldwide service
A comparison of melting furnaces
With this background of immense experience, we also plan and build
When planning a melting operating, at some stage the question of the type
complete centrifugal casting plants, cokeless cupola furnaces and
of melting furnace to be installed will be raised. In principle there are two
control systems for manufacturing business all over the world.
different processes to choose from: Cupola furnaces and electric melting
furnaces.
Each of these systems has its own individual design which depends on
Service
Planning
Cokeless
cupolas
from Düker
Installation
2
Cupolas melt pig iron, defective castings and steel scrap and use coke, min-
Since we have also been using our systems for many years for our
eral oil or natural gas as fuel. They are the preferred continuous melting units
own production operation, our customers have a unique range of
for iron foundries since they can supply high quantities in constant quality.
Certified quality:
As the name suggests, electric furnaces use electricity to power them and
We received certification to DIN EN ISO 9001
are used for discontinuous applications with frequent analysis changes.
way back in 1993. Since then our quality man-
expertise at their disposal, which is constantly being updated and
extended.
Implementation/
Design
Training
the site conditions and the specific requirements of the customer.
We thereby offer our customers worldwide a convenient and
agement system has been updated and im-
customized all-round service which is virtually unique – from
proved on an on-going basis by means of regu-
the design, planning and construction to assembly, commissioning
lar inspections and also internal and external
and training your personnel – you receive everything from a single
audits.
source.
3
Cokeless cupolas from Düker – economical and environmental
Energy consumption
Cokeless cupolas ideally use natural gas as fuel.
This gives them a better heat balance and con-
Convincing benefits
in MJ
1525 °C tapping temp./ 1 ton liqud iron GJS
siderably better emission values.
4975
Overall this results in a whole series of major ben-
Charging
• expensive coke stores not required
3926
Melting
efits compared to alternative furnace systems such
as coke-fired cupolas.
2443
• the melting process is easier to control with
natural gas
1000
• less slag formation
• cleaner primary energy
HW cupola
liningless
KW cupola
secondary wind
and O2
Cokeless cupola,
gas-fired with
superheater
in %
1500 °C cupola tapping temp.
70
50
KW = Cold wind
HW = Hot wind
KW cupola,
secondary wind
and O2
Hw-Lz = Hot wind for long term campaign
HW cupola,
Cokeless cupola,
without material cool- KW + O2 , electric
ing, daily alternating superheating
operating mode
Carbon dioxide emissions kg/ T Fe
4500
4000
3500
3000
2500
2000
1500
1000
500
4
Coke cupola
2,0
200
1,5
KWh
b.) Auxiliary mode
KWh
25,0
Shaft-blast furnace
kg
5-8
Siphon
kg
0,7
Superheater
kg
0,5
1.4 Water consumption
m3
0,4
1.5 Oxygen
m3
19,7
1.3 Refractory consumption
Superheater
• accurate carburisation
• base iron does not have to be desulphurised
1.6 Metallic charging
• uniform analysis is possible
20
• excellent flow properties of the molten metal
Steel
%/t
25 - 35
• very low volumes of transition iron
Pig iron
%/t
20 - 30
• ideal melting losses for C, Si and Mn
Returns
%/t
35 - 55
Carburisation
%/t
1,1
Si-blanks
%/t
0,8
Ceramic spheres
%/t
0,95
Slag-forming constituent
%/t
0,3
Economy
1.7 Alloy-materials/Additives
• no air pollution with sulphur compounds
• no CaC2 slag from GJS production
• reduced nuisance emissions
1,0
150
100
a.) Superheater
• low level of pollutants in the slag
Cokeless cupola
300
250
1.2 Electrical energy consumption
Environment
2,5
400
350
48 - 52
• perfect energy use with duplex system
Sulphur dioxide emissions kg/ T Fe
450
m
15,0
• low costs for dust extraction
Energy use MJ/ T Fe
Melting
KWh
• simple conversion of existing cupolas
Environmental balance of the cokeless, natural gas-fired cupola
600
3
Keeping warm
• low purchase cost for new systems
O2 = Oxygen
m3
• the melting process can be interrupted without
• no sulphur pick-up
HW-Lz cupola
with lining
Preheating the furnace
30
10
KW cupola,
secondary wind
or O2
1.1 Natural gas consumption
64,0
Quality
HW-Lz cupola
liningless
Consumption/t GJS
KWh
40
KW cupola
Unit
Superheating
• low use of additional electrical energy required
60
Energy
• constant tapping temperature with flexible output
any problem
Energy use for melting in cupolas
Operating costs for melting GJS base iron
in cokeless cupolas
• low duct content in the flue gas
0,5
50
5
Cokeless cupolas from Düker – added value that pays dividends every day
This is how a cokeless cupola works
Charging and operating data of the cokeless cupola
with
ceramic spheres. Then the preheating
phase begins which takes around 45 minutes.
After this the cokeless cupola is fed with metallic
GJL
GJL
First of all the grating in the furnace is covered
Charge material
charge materials and slag-forming constituents.
Return (kg)
400
Cast iron scrap (kg)
400
Steel scrap (kg)
200
GJS
350
250
Slag-forming constituents (kg)
35
30
flow through the ceramic sphere bed and inten-
Consumption of natural gas (m 3)
50
50
sively heat the charge material. This melts and
Consumption of ceramic spheres (kg)
9,5
9,5
flows on to the ceramic spheres. Thereby it is su-
Consumption of refractory materials (kg)
9
9
Consumption of water (m 3)
0,4
0,4
Consumption of electricity (KWh)
80
80
Combustion air (m 3)
500
500
Flue gas (m3)
600
600
perheated and drips into the bottom of the furnace.
Shaft cooling system
Blast pipe
Slag and iron are finally separated from each other
in the furnace’s siphon.
Just 15 minutes after the first furnace charge has
Ceramic
sphere bed
Water-cooled grid
GJS
400
Pig iron (kg)
The hot combustion gases from the gas burners
Control equipment made by Düker
With our process control systems you can control all the parameters for your cupola and the
periphery conveniently from your PC.
been inserted, the first iron will flow into the elec-
A clear visualisation system shows you all the
trically heated superheater where the required
temperature and alloy are adjusted.
characteristic data permanently and you can
All figures are relative to one ton of cast iron
then adjust them and save them if necessary.
Gas burner
Analysis of the production of GJL/GJS
This ensures the uniform high quality of the
The furnace gas generated by the melting process
melting process.
C
Si
Mn
P
S
GJL cupola tapped iron 1400 - 1420 °C
2,8
1,8
0,4
0,06
0,03
GJL liquid iron 1480 °C at superheater
3,3
2,3
0,6
0,06
0,03
GJS cupola tapped iron 1400 - 1410 °C
2,6
1,6
0,2
0,04
0,09
GJS liquid iron 1520 °C at superheater
3,7
1,6
0,2
0,04
0,09
is continuously exhausted, cooled and purified by
dry filters in the top section of the furnace in a
Siphon
gas/air exchanger.
Superheater
Inductor
We actually make our control systems at our plant
in Karlstadt, Germany. They undergo ongoing development and improvements. This means that
our customers can rely on the fact that they
will always have the very latest technology
– for years to come.
Figures in %
Modernisation of existing cupolas
Training and maintenance
We can convert existing cupolas which can still use as a fuel to gas opera- Naturally we are also available for you after the
tion without any problems. In this respect we also will inspect your furnace commissioning procedure for your new or modernthoroughly to establish its efficiency and function. It is of no consequence ised cupola furnace. For example we can provide
to us whether it is one of our systems or was supplied by another manufac- training courses and advanced training for
turer. Which of the various possible solutions ultimately makes sense will be your personnel, keep your system working cordetermined individually for each customer.
rectly with regular service and maintenance
work and also keep you up to date with possible
modernisation options.
6
7
ENGINEERING
GLASS LINING TECHNOLOGIES
JObbING FOUNDRy
FITTINGS AND vALvES
DRAINAGE TECHNOLOGy
Kuttner North America
211 N. Franklin
Street,
BoxKGaA
343
Düker
GmbHPO
& Co.
Port Washington, WI 53074
Würzburger Straße 10
D-97753
/Main
Phone
+1 Karlstadt
262 284 4483
Fax +1+49
262
284791-235
4483
Phone
9353
Fax +49 9353 791-175
www.KuttnerNA.com
Internet: www.dueker.de
[email protected]
10.09 Subject to technical changes and printing errors.
E-Mail: [email protected]

Download Report