OF

MANUFACTURING SCIENCES 104

MELTING PRACTICES AND FURNACES

Submitted in the partial fulfilment of the Degree of Bachelor of Technology

(Integrated)

In Mechanical Engineering

SUBMITTED BY:- GUIDED BY:-

Name- NIKHIL LADHA Mr. Sudarsi Rakesh

Regd. No- 11003993
Roll no.- RE4001A23
Section- E4001
 ACKNOWLEDGEMENT

I take this opportunity to present my votes of thanks to all those

guidepost who really acted as lightening pillars to enlighten our way
throughout this project that has led to successful and satisfactory
completion of this study.

We are really grateful to our teacher Mr. Sudarsi Rakesh

for providing us with an opportunity to undertake this project in this
university and providing us with all the facilities. We are highly thankful
to him for his active support, valuable time and advice, whole-hearted
guidance, sincere cooperation and pains-taking involvement during the
study and in completing the assignment of preparing the said project
within the time stipulated.

Lastly, We are thankful to all those, particularly the various friends , who
have been instrumental in creating proper, healthy and conductive
environment and including new and fresh innovative ideas for us during
the project, their help, it would have been extremely difficult for us to
prepare the project in a time bound framework.

Name- Nikhil Ladha

Regd.No- 11003993

Rollno. - RE4001A23
 TABLE OF CONTENTS

 Introduction
 Melting Practices-
 Melting Process
 Method of melting metals
 Melting Practices
 Furnaces-
 Definition
 Types of Furnace
 Conclusion
 References
 INTRODUCTION

In this term paper, the melting practices and furnaces are discussed in brief. The process of
melting is an important part of Casting. The melting practices include a metallic material
stacked in a melting furnace which is melted by heating it directly with the flame from a fuel
burner using an oxygen gas. Melting practices of metals are carried out in furnaces. Furnaces
are the containers in which the melting process is carried out. Some discussions about these
furnaces are included in this term paper.

Melting is an equally important parameter for obtaining a quality castings. A number of

furnaces can be used for melting the metal, to be used, to make a metal casting. The choice of
furnace depends on the type of metal to be melted. Some of the furnaces used in metal casting
are as following:-

 ELECTRIC FURNACES

 CUPOLA FURNACES

 CRUCIBLE FURNACES

 GAS FURNACES

 INERT GAS FURNACES

 MELTING PRACTICES
Melting:-
A process is disclosed for burning hydrocarbons in the vapours emitted from contaminated
metallic scrap in a re-melt furnace having a molten bath therein. The furnace comprises a
charging chamber and a heating chamber separated by a wall. The wall is provided with at
least one lower opening and at least one upper opening through which the chambers are in
communication above and below the level of molten metal. Scrap is charged into the
charging chamber where molten metal ablatively melts the charge. Oil and other surface
contaminants evolving from the charge are drawn through the upper opening in the wall into
the heating chamber by maintaining a pressure in the heating chamber less than, or negative
in relation to, the pressure in the charging chamber. The hydrocarbon vapours burn in the
heating chamber and contribute heat of combustion. Controlling the level of pressure
differential between the heating chamber and the charging chamber facilitates substantial
benefits in efficiency and economy.

Method of melting metals:-

In this method, a metallic material stacked in a melting furnace is melted by heating it
directly with the flame from a fuel burner using an oxygen gas having a purity of 60 to 100%
as a combustion assisting gas. The oxygen gas is burned at an oxygen-to-fuel ratio of 0.55 to
0.99, while the unburned portion of the combustion gas is allowed to burn by O2 supplied
separately through oxygen lances. Meanwhile, the metallic material is preheated by burning
the unburned portion of the combustion gas, whereas the combustion assisting gas is heated
before it is fed to the burner.

Melting Practices:-
This invention relates to an improved method of melting metal, particularly reactive metals,
such as aluminium, wherein heated molten metal is withdrawn from a first chamber and a
portion of the withdrawn molten metal is transferred to a second chamber containing solid
metal so as to melt same and a portion of the withdrawn metal is re-circulated to the first
chamber so as to maintain melt homogenuity therein.

A process for melting metal in a shaft furnace operated without coke using a liquid or
gaseous fuel, whose combustion products initially heat the molten metal which has collected
below the furnace hearth in furnace shaft to the desired tapping temperature, followed by the
introduction thereof into the furnace shaft for melting the metal. Furnace shaft and furnace
hearth are separated by a water-cooled grid , which carries the charge introduced into the
shaft. The flame temperature of burner is controlled through preheating the combustion air.
The combustion air is recuperatively heated by the waste gases of the shaft furnace. The heat
transfer in the recuperator is variable and can be influenced by the supply of cooling air to
the waste gases prior to recuperation, by a controllable induced draft blower behind the
recuperator and/or after-burning of the waste gases prior to the introduction thereof into the
recuperator. Most of the foundries operate on a batch basis. A number of sand moulds are
prepared and kept ready for pouring before the molten metal is prepared. This process may
take a few days to weeks depending upon the size and nature of the foundry plant. Thus it
becomes necessary only to start melting may be once a week or so. Metal Quality is affected
by oxidization and losses due to vaporization, which can adversely affect the chemical
properties of the alloy being melted. Similarly the types of refractory used are matched to
the basicity or acidity of the metal and/or its resultant (Dross or slag).

Melting a charge comprising alloys of iron and chromium in an electric arc furnace to
achieve metal of maximum cleanliness with minimum oxide inclusions but of high-carbon
content, and then ridding the metal of carbon in a vacuum furnace by way of readily
reducible oxides and low pressure.

Melting process in a cupola furnace:-

To operate the cupola, first, the drop doors at the bottom are closed and a sand bed with a
gentle slope towards the tap hole is rammed. Then a coke bed of suitable height is prepared
above the sand bottom and ignited through the tap hole or any other hole. When the coke bed
is properly ignited, alternate layers of charge, flux and coke are alternatively fed into the
cupola through the charging door maintaining necessary proportions and rate of
charging. The charge is allowed to soak in the heat for a while, and then the air blast is turned
on. Within about 5 to 10 minutes, the molten metal is collected near the tap hole. When
enough molten metal is collected in the well of the cupola, the slag is drained off through the
slag hole before opening the tap hole. The molten metal is collected in the ladles and then
transported to the moulds into which it is poured with a minimum time loss.

The fluxes are added in the charge to remove the oxides and other impurities present in the
metal. The flux most commonly used is limestone (CaCO3) in a proportion of about 2 to 4 %
of the metal charge. Some of the other fluxes that may also be used are dolomite, sodium
carbonate and calcium carbide. The flux is expected to react with the oxides and form
compounds which have low melting point and also lighter. As a result, the molten slag tends
to float on the metal pool and thus, can very easily be separated. Here is a graph showing the
variation of costs of induction melting and cupolas melting:-
Melting process in a Blast Furnace:-
Hot metal is transported by sub car to a Basic Oxygen Process (BOP) facility, where it is
heated, chemically adjusted, and converted to liquid steel.  Its composition and temperature
are further modified at a ladle metallurgy facility and/or vacuum degassing facility, in order
to meet specifications.  The molten steel is then transported by ladle to the dual strand slab
caster, where it is placed on a rotating turret.  Once in position, the steel flows from the ladle
into the tundish below.  As it moves down through the moulds, the steel cools, solidifies, and
slabs are formed.  The solid slabs are cut to length by torches, then they are rolled, treated
and formed into coils.

The production of hot metal in the blast furnace is the first and most crucial step in making
steel products.  Inputs charged into the furnace at its top, the "burden”, fall into four
categories. The first category, iron-bearing materials, such as iron ore, sinter, pellets, mill
scale, and steel scrap, contribute to tonnage and quality of the hot metal.  The second
category, coke, which serves as fuel, provides the carbon required for the iron bearing
materials to be reduced.  The final two categories, fluxes and trims, separate the impurities
from the hot metal following the reduction phase.  Examples of fluxes and trims are
limestone, dolomite, gravel and various manufactured materials.  For all of these materials,
their pH determines their classification as fluxes or trims.
Heated air, enriched with natural gas and/or coke oven gas, is injected into the furnace
through jets called “tuyeres”, resulting in the combustion of carbon in the coke.  This
exothermic reaction reduces the burden and facilitates several chemical reactions, resulting in
the melting and reduction of the iron ore and the formation of liquid slag.   In normal
operation, the furnace contains three casts at different height levels; the cast at the bottom is
being tapped, the middle two are descending and are undergoing reduction, and the charge for
a new cast is being added. The materials in a cast descend more rapidly near the furnace
centre where the hot air is directed. Hence there is some mixing of the materials in adjacent
casts.
Alloys have a wide spectrum of temperatures that they melt at; the list below
should illustrate this point:-

Metal Alloy Type Temp Range (Celsius)

Zinc 345-455

Aluminium 620-735

Magnesium 620-735

Copper 908-1180

Cast Irons 1340-1480

High Manganese Steel 1400-1455

Monel (70N, 30Cu) 1370-1540

Nickel Based Super Alloys 1430-1540

High Alloy Steels 1480-1600

High Alloy Irons 1540-1650

Carbon & Low Alloy Steel 1565-1700

Titanium 1700-1820

Zirconium 1845-1900

Table : Melting point of common materials

 FURNACES
After moulding, melting is the major factor which controls the quality of the casting. There
are a number of methods available for melting foundry alloys such as pit furnace, open hearth
furnace, electric furnace, rotary furnace, cupola furnace, gas furnace etc. The choice of
furnace type is based on these four factors:-

 Alloy Type

 Metal Quality

 Production Demands

 Economics

A refractory lined melting furnace particularly suited for separation of non-ferrous metals
with embedded or attached ferrous components, includes a casing or body pivotally mounted
and tilted by means of fluid operators. The interior is divided by two vertical walls into a
combustible waste burning portion for the generation of combustible gases to assist in heating
the furnace, and a melt chamber into which a variety of metallic waste can be charged for
melting. A conventional fire burner is supplied to the melt chamber. The temperature of the
melt chamber is raised to the melting point of the metallic waste material having the lowest
melting point, e.g. aluminium, and when the aluminium is melted, the aluminium runs
through drainage apertures into a liquid metal holding chamber provided on the floor of the
melt chamber. When the molten metal has drained, the furnace is tilted to discharge the
remaining scrap out through rake-out doors at the rear of the melt chamber. The sequence is
repeated with heat being supplied from the combustible gases formed in the combustible
waste burning portion, until the storage chamber is full whereupon the furnace is tilted and
the molten metal discharged from a tapping hole in the front of the storage chamber. Here is a
diagram showing a melting furnace:-
Some types of furnaces have been discussed below:-

 ELECTRIC FURNACES:-

For heavy steel castings, the open hearth type of furnaces with electric arc would be
suitable in view of the large heat required for melting. Due to good temperature control and
flexibility of operation, this furnace is widely used for melting for small to medium sized
castings in ferrous as well as non-ferrous alloys. There are three types of electric furnaces on
the basis of source of heating (Arc, Resistance, and Induction). The electrically heated tilting
crucible furnaces of the K and KF series are characterized by high melting performance with
very uniform temperature distribution in the melt. Aluminium and brass can be melted in the
1200 °C version. The 1300 °C version can also be used to melt bronze alloys. For faster
heating-up cycles in batch operation furnaces can be insulated with fiber resulting in lower
heat storage. The electrically heated tilting crucible and bale-out furnaces of the KC and TC
series are characterized by a higher melting performance than achievable with wire heated
melting furnaces. These furnaces are designed for permanent operation at working
temperatures.

 CUPOLA FURNACES:- It consists of a cylindrical steel shell with its interior lined
with heat resisting fire bricks. It has drop doors at the bottom. After closing the door a
proper sand bed is prepared. This sand bed provides necessary refractory bottom for
the molten metal and the coke. Immediately above the sand bed is the metal
tapping hole which is initially closed with clay till the molten metal is ready for
tapping. Above the metal tapping hole normally in a position opposite to is the slag
hole through which the slag generated during the melting process is tapped. Most of
the foundries operate on a batch basis. A number of sand moulds are prepared and
kept ready for pouring before the molten metal is prepared. This process may take
a few days to weeks depending upon the size and nature of the foundry plant. Thus
it becomes necessary only to start melting may be once a week or so.

Cupola has been the most widely used furnace for melting cast iron. This is because of the
low cost of melting. However, less control of the final quality, and the losses involved would
call for some change in the choice. Therefore liquid or gas fired furnaces and electric
furnaces are becoming popular because of their better control of melting process and low
melting losses. But these are more expensive compared to the solid fuel fired furnaces and
therefore the higher cost is to be justified based on the better control of quality achieved in
terms of the composition and temperature. The cupola is charged with wood at the bottom.
On the top of the wood a bed of coke is built. Alternating layers of metal and ferrous alloys,
coke, and limestone are fed into the furnace from the top. The purpose of adding flux is to
eliminate the impurities and to protect the metal from oxidation. Air blast is opened for the
complete combustion of coke. When sufficient metal has been melted that slag hole is first
opened to remove the slag. Tap hole is then opened to collect the metal in the ladle.
  CRUCIBLE FURNACES:- Crucible furnaces are small capacity typically used for
small melting applications. Crucible furnace is suitable for the batch type foundries
where the metal requirement is intermittent. The metal is placed in a crucible which is
made of clay and graphite. The energy is applied indirectly to the metal by heating the
crucible by coke, oil or gas. The heating of crucible is done by coke, oil or gas-

Coke-Fired Furnace

 Primarily used for non-ferrous metals

 Furnace is of a cylindrical shape
 Also known as pit furnace
 Preparation involves: first to make a deep bed of coke in the furnace
 Burn the coke till it attains the state of maximum combustion
 Insert the crucible in the coke bed
 Remove the crucible when the melt reaches to desired temperature

Oil-Fired Furnace

 Primarily used for non-ferrous metals

 Furnace is of a cylindrical shape
 Advantages include: no wastage of fuel
 Less contamination of the metal
 Absorption of water vapour is least as the metal melts inside the closed metallic
furnace.

 GAS FURNACES:- The gas or oil fired tilting crucible furnaces of the KB series are
characterized by their high melting performance. They are perfectly suited for the
melting of aluminium and other nonferrous alloys. The use of high-quality insulation
materials results in very low power requirements. The two-stage burner can be
configured for either gas operation or oil operation. The gas or oil fired crucible
furnaces of the TB series are characterized by their high melting performance. They
are the work horse for melting operation but also for holding of aluminium and zinc.

 INERT GAS FURNACES:- Built-in water cooling panel protects furnace door and
sealing silicone material during furnace operation, to ensure air tightness. It has a
Built-in computer interface. Overheat protection shuts down the furnace when furnace
temperature exceed certain range. Thermo damage protection shuts down the furnace
when any of the thermocouples is broken. Power failure protection resumes furnace
operation from the point left off from the failure. Temperature variation protection
shuts down furnace when SV and PV difference is beyond desired value.

An analysis and control device for glass furnaces is of the fuzzy-controller type and
uses a control algorithm which receives information relating to the operation of the
furnace coming from sensors and from detection means provided on this furnace, as
well as set point values input manually by operators. This control algorithm delivers
control signals to the various actuators and control means of the furnace. A predictive
system, of the neural- and/or fuzzy-type is included which depends on the state of the
furnace and on the information about the change in production over time. It defines
the various set point values to be assigned to all the furnace actuators, so as to ensure
optimum operation for each production phase. The set point values constitute input
values for the fuzzy-logic algorithm which controls the furnace.

Fig:- BLAST FURNACE

 CONCLUSION

Thus melting practices play an important role in the field of manufacturing. These processes
are basically included in the Casting process. The metal is to be first melted with the help of
melting processes and then poured into the mould box for obtaining the required shape and
geometry. The melting processes are carried out in different furnaces as per the demand of
the manufacturer. The furnaces are selected as per the maximum temperature that they can
resist and also must be economically reasonable so as to make the entire process feasible.
 REFERENCES

www.google.com Universal search website

www.wikipedia.com Educational search website
www.scienceworld.com Science search website
Fundamentals of Modern
Manufacturing Book by Mikell P. Grover