Furnaces Report

FURNACE RESEARCH
MDP251 Casting and Welding 1
MANF Program
Names:Omar alaa eldin mohamed 18p9390

Seif Khaled Seif Elmolook Mohamed Ibrahim 21p0143
May Fadl Helil 18p8064
Submitted to: DR. Ramadan Aljumsy

Eng. Basem tarek
Table of Contents
1. INTRODUCTION:................................................................................................................. 2
2. CASSIFICATION OF FURNACES: ........................................................................................... 2
3. Types of furnaces: .............................................................................................................. 3
3.1. Crucible Furnaces ....................................................................................................................4
3.2. Pit furnace ..............................................................................................................................4
3.3. Tilting crucible furnace ............................................................................................................5
3.4. The Cupola Furnace .................................................................................................................5
3.5. Induction furnace ....................................................................................................................7
3.6. Arc resistance furnace .............................................................................................................8
1. INTRODUCTION:
Industrial furnaces are the workhorses of manufacturing and processing
industries, designed to handle high-temperature operations for various
purposes. These robust systems serve in the production of metals, ceramics,
glass, chemicals, and other materials by subjecting raw materials to extreme
heat within controlled environments. Their functionality spans a wide range
of applications, including melting, annealing, heat treatment, forging, and even
chemical reactions.
These furnaces are engineered to withstand intense heat and maintain precise
temperature control, often using specialized materials and insulation to
ensure efficiency and safety. Industrial furnaces come in diverse types, such as
blast furnaces, rotary kilns, electric arc furnaces, and more, each tailored to
specific industrial processes.
Their crucial role in industrial processes makes them pivotal for the
production and refinement of various goods, from metals used in construction
to ceramics employed in electronics. The advancements in furnace technology
continue to drive innovation and efficiency in industrial operations, allowing
for more precise control over heat treatment processes and contributing
significantly to the quality and consistency of manufactured products.
2. CASSIFICATION OF FURNACES:
1- Fuel Source:
• Gas Furnaces: Utilize natural gas or propane as the primary fuel source
for heating.
• Oil Furnaces: Burn heating oil (usually No. 2 fuel oil) to generate heat.
• Electric Furnaces: Rely on electricity to produce heat, often using
heating elements.
2- Operating Temperature:
• Low-Temperature Furnaces: Operate at temperatures up to 1000°C
(1832°F), used for processes like annealing and aging.
• Medium-Temperature Furnaces: Operate between 1000°C to 2000°C
(1832°F to 3632°F), employed in processes like forging and tempering.
• High-Temperature Furnaces: Operate above 2000°C (3632°F), used in
applications like melting metals, ceramics, or glass.
3- Construction and Design:

• Batch Furnaces: Used for intermittent operations, where materials are
loaded, processed, and then unloaded before reloading for the next
cycle.
• Continuous Furnaces: Operate continuously, with a steady input and
output of materials, ideal for high-volume production.
4- Function and Purpose:

• Melting Furnaces: Specifically designed for melting metals or other
materials.
• Heat Treatment Furnaces: Used for processes like annealing, tempering,
quenching, and hardening of materials.
• Combustion Furnaces: Employed for chemical processes or waste
disposal, often at high temperatures.
• Industrial Ovens: Function as furnaces but are optimized for baking,
curing, drying, or other specific applications.
5- Specialized Furnaces:
• Blast Furnaces: Typically used in the iron and steel industry for smelting
operations.
• Muffle Furnaces: Enclosed furnaces used for controlled atmosphere or
protective gas heating.
• Vacuum Furnaces: Operate in a vacuum or controlled atmosphere to
prevent oxidation, widely used in aerospace and metallurgy for
specialized processes.
3. Types of furnaces:
Crucible furnaces
Pit furnace
Tilting crucible furnace.
Cupola furnace
Induction furnace
Arc resistance furnace
3.1. Crucible Furnaces
Crucible furnaces are one of the oldest and
simplest types of melting unit used in the
foundry. The furnaces uses a refractory crucible
which contains the metal charge. The charge is
heated via conduction of heat through the walls
of the crucible. The heating fuel is typically coke,
oil, gas or electricity. Crucible melting is
commonly used where small batches of low
melting point alloy are required. The capital
outlay of these furnaces makes them atractive to small non-ferrous foundries.
Crucible furnaces are typically classified according to the method of removing

the metal from the crucible:
1. Tilting furnace, in which the molten metal is transferred to the mould

or ladle by mechanically tilting the crucible and furnace body.
2. Lift-out furnace, in which the crucible and molten metal are removed
from the furnace body for direct pouring into the mould.
3. Bale-out furnace, in which the metal is ladled from the crucible to the
mould.
3.2. Pit furnace

Pit furnace is a type of a furnace bath which is
installed in the form of a pit and is used for melting
small quantities of ferrous and non ferrous metals
for production of castings. It is provided with
refractory inside and chimney at the top. Generally
coke is used as fuel. It is provided with refractory
lining inside and chimney at the top. Natural and
artificial draught can be used for increasing the
capability towards smooth operation of the furnace.
The pit furnace is a vertical orientation batch
furnace used for a variety of processes. Designs can
be provided for atmosphere or direct fired
processes. Furnaces are available with retorts or without depending on
process requirements.
3.3. Tilting crucible furnace
Gas or oil fired tilting crucible furnaces are used
for melting and holding non- ferrous metals such
as aluminum, brass or bronze.
Our crucible furnaces are robustly built and
highly energy efficient thanks to a very thick steel
boiler, top quality refractory and insulating
materials and an optimal combustion system
Standard supply
• Furnace complete with silicon
carbide (SiC) crucible and bottom plate
• Advanced automatic combustion equipment.
• Control panel with programmable clock
• Hydraulic tipping system with hydraulic unit
Options
• Heat recovery
• Automatic charger for cast iron returns / sprues
• Connection cables
• Work platform
• Cleaning tools
• Replacement Crucible and bottom plate (Foundry Consumable)
3.4. The Cupola Furnace
For many years, the cupola was the primary method of melting used in iron
foundries. The cupola furnace has several
unique characteristics which are responsible
for its widespread use as a melting unit for
cast iron.
1. The cupolas is one of the only methods

of melting which is continuous in its
operation
2. High melt rates
3. Relatively low operating costs
4. Ease of operation
In more recent times, the use of the cupola has declined in favour of electric
induction melting, which offers more precise control of melt chemistry and
temperature, and much lower levels of emissions.
The construction of a conventional cupola consists of a vertical steel shell

which is lined with a refractory brick. The charge is introduced into the
furnace body by means of an opening approximately half way up the vertical
shaft. The charge consists of alternate layers of the metal to be melted, coke
fuel and limestone flux. The fuel is burnt in air which is introduced through
tuyeres positioned above the hearth. The hot gases generated in the lower
part of the shaft ascend and preheat the descending charge.
Most cupolas are of the drop bottom type with hinged doors under the hearth,
which allows the bottom to drop away at the end of melting to aid cleaning
and repairds. At the bottom front is a taphole for the molten iron at the rear,
positioned above the taphole is a slaghole. The top of the stack is capped with
a spark/fume arrester hood.
Typical internal diameters of cupolas are 450 mm to 2000 mm diameter wich

can be operated on different fuel to metal ratios, giving melt rates of
approximately 1 to 30 tonnes per hour.
A typical operation cycle for a cupola would consist of closing and propping
the bottom hinged doors and preparing a hearth bottom. The bottom is
usually made from low strength moulding sand and slopes towards a tapping
hole. A fire is started in the hearth using light weight timber, coke is charged
on top of the fire and is burnt by increasing the air draught from the tuyeres.
Once the coke bed is ignited and of the required height, alternate layers of
metal, flux and coke are added until the level reaches the charged doors. The
metal charge would typically consist of pig iron, scrap steel and domestic
returns.
An air blast is introduced through the wind box and tuyeres located near the
bottom of the cupola. The air reacts chemically with the carbonaceous fuel
thus producing heat of combustion. Soon after the blast is turned on, molten
metal collects on the hearth bottom where it is eventually tapped out into a
waiting ladle or receiver. As the metal is melted and fuel consumed, additional
charges are added to maintain a level at the charging door and provide a
continuous supply of molten iron.
At the end of the melting campaign, charging is stopped but the air blast is
maintained until all of the metal is melted and tapped off. The air is then
turned off and the bottom doors opened allowing the residual charge material
to be dumped.
3.5. Induction furnace

An induction furnace is a type of electric furnace that uses heat generated by
its own electrical resistance to melt a charge of scrap.
They are ideal for melting and alloying a wide range of metals with minimal
melt losses, but little metal refining is possible. Based on the theory of Electro
Magnetic Induction, it uses induction to heat a metal to its melting point. A coil
carrying alternating electric current surrounds the metal container or
chamber in
the induction furnace.
Eddy currents are induced in the metal (charge), and the circulation of these
currents produces extremely high temperatures, allowing the metals to be
melted and alloys of exact composition to be formed.
There are two main types of induction furnace: coreless and channel.
• Coreless induction furnaces
The heart of the coreless induction furnace is the coil,

which consists of a hollow section of heavy duty, high
conductivity copper tubing which is wound into a
helical coil. Coil shape is contained within a steel shell
and magnetic shielding is used to prevent heating of the
supporting shell. To protect it from overheating, the coil
is water-cooled, the water bing recirculated and cooled
in a cooling tower. The shell is supported on trunnions
on which the furnace tils to facilitate pouring.
• Channel induction furnaces
The channel induction furnace consists of a

refractory lined steel shell which contains the
molten metal. Attached to the steel shell and
connected by a throat is an induction unit which
forms the melting component of the furnace. The
induction unit consists of an iron core in the form of
a ring around which a primary induction coil is wound. This assembly forms a
simple transformer in which the molten metal loops comprises the secondary
component. The heat generated within the loop causes the metal to circulate
into the main well of the furnace. The circulation of the molten metal effects a
useful stirring action in the melt.
Channel induction furnaces are commonly used for melting low melting point
alloys and or as a holding and superheating unit for higher melting point
alloys such as cast iron. Channel induction furnaces can be used as holders for
metal melted off peak in coreless induction induction units thereby reducing
total melting costs by avoiding peak demand charges.
3.6. Arc resistance furnace

Electric arc furnaces may be categorised as direct arc or indirect arc. Both
types of units are suited for the melting of high melting point alloys such as
steels. They may be lined with acid or basic refractories.
• Direct arc furnaces
Direct arc furnaces are very popular for the melting of alloy steels and range
in size from a few kilograms, for laboratory units, to in excess of 100 tonnes
per batch. Typically units found in foundries are in the range of 1 to 10 tonnes.
The furnace generally consists of a cylindrical steel shell which is lined with
acid or basic refractories. The roof which can normally swing away to
facilitate charging, generally contains three carbon electrodes operating on a
high tension three-phase power supply. These electrodes protrude vertically
through the roof and an electric current passes directly through them and into
the metal bath. The distance between the electrodes and the metal bath is
automatically controlled and determines the power input into the bath.
These furnaces generally have a door at the back for alloying, oxygen lancing
and slag removal purposes, and a pouring spout at the front. The entire unit is
capable of being tilted for discharge of the melt through the pouring spout.
Some of the advantages of direct arc furnaces include high melt rates, high
pouring temperatures and excellent control of melt chemistry.
• Indirect arc furnaces
Generally consist of a horizontal barrel

shape steel shell lined with refractories.
Meltin is effected by the arcing between
two horizontally opposed carbon
electrodes. Heating is via radiation from
the arc to the charge. The barrel shaped
shell is designed to rotate and reverse
through approximately 180°C in order
to avoid excessive heating of the
refractories above the melt level and to
increase the melting efficiency of the
unit.Indirect arc furnaces are suitable
for melting a wide range of alloys but are particularly popular for the
production of copper base alloys. The units operate on a single-phase power
supply and hence the size is usually limited to relatively small units.

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FURNACE RESEARCH

MDP251 Casting and Welding 1

Names:Omar alaa eldin mohamed 18p9390

May Fadl Helil 18p8064

Submitted to: DR. Ramadan Aljumsy

3- Construction and Design:

4- Function and Purpose:

Crucible furnaces are typically classified according to the method of removing

1. Tilting furnace, in which the molten metal is transferred to the mould

3.2. Pit furnace

1. The cupolas is one of the only methods

The construction of a conventional cupola consists of a vertical steel shell

Typical internal diameters of cupolas are 450 mm to 2000 mm diameter wich

3.5. Induction furnace

• Coreless induction furnaces

The heart of the coreless induction furnace is the coil,

• Channel induction furnaces

The channel induction furnace consists of a

3.6. Arc resistance furnace

• Direct arc furnaces

• Indirect arc furnaces

Generally consist of a horizontal barrel

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