This thesis was contributed by

lr. F. H. Prescott

under the date indicated by the department stamp, to re-
place the original which was destroyed in the fire of
March 5, 1917.

i.
WN
 

 

 

 
HAT BALANCE ON THs FOUNDRY CUPOLA
AT
MICHIGAN AGRICULTURAL COLLEGE

A Thesis Submitted to
The Faculty of

MICHIGAN AGRICULTURAL COLLEGE

By
F. H. Prescott H. &. Spurr
R. E. Decker R. &. Olin.

Candidates for the Degree
of

Bachelor of Science.

June, 1915.

 

 
THESIS
4

HSAT BALANCS OM FOUNDRY CUPOLA.

 

The object of this thesis is to show the eources
of heat and the heat distribdvution in the foundry cupola;
also the amount of logs and gain in the constituent elements
of the iron from the oharging door to the spout. Our tests,
which were made upon the College Cupola, have shown that
about twenty percent of the available heat goes to melt the
iron, the largeet of the remainder going into the etack cases.
It wse aleo determined that the elements in the charged irons
atl decreased more than the iron itself, except sulfur which
showed an inoresse due to the high percentage of sulfur in
the coke ueed.

The apparatuses and metnods used in determining these
resulte were rather simple. see illustration. sne results
of the teets were secured by messuring the following quanti-
ties an indicated.

Charging Floor:- Weighing of iron and coke charged
by platform scales.

Analysis of stack gases at churgimgdoor., ine
gases were drawn through a eset of pipes by means of an arpi-
rator and were later analyzed in an Orsat apparatus. ihe
method of analyzing the gae used on the first teste was to
draw the gae directly into the Oreat apparatus and ahalyze at
once. Tne results were very unsatisfactory due to trouble in
getting a good sample, and the time necesusry to analyze the

\
gas.

ECR Ke.
264819
 

 

 

De

A new method was then devised as follows: <A bottle
with a two hole stopper, in which two glass tubes, one short
and one long, had been inserted, wae filled with water and
connected with an aspirator suction and the eample pire. ine
suction draws tne gas from the stack into the bottle, dis-
placing the water. Ine samples can then be analyzed a conven-
ient, which makes e satisfactory method,

she temperature of the gases at the charging door ws
meanured Dy @ pyrometer. The photograph shows the arran;e-
ment of the apparatus.

Blast and Blower:- The velocity and pressure of the
blast wes measured in the blast pipe by means of a pitot
tube. From this data, the weight of air used during the
test wae calculated. The humidity was measured by a whirling
hygrometer, the temperature of the entering air was also
measured, and the horse-power required to dfive the fan wae
measured dy means of a vOltmeter and ammeter. The R. ?P. #.
of the motor was taken and from it the Kk. ?. kh. of the fan
wee caloulated.

In the firet two tests, tne fan wis set close to
the cupola and the short length of pipe made it impossible
to get good reliable readings of the pitot tube without
making e traverse. To correct this condition, the fan was

moved back from the cupola and a longer piece of pipe used,

the pitot tube being fastened in permanently. The result

was a more estisfactory set of readings.
- 3-

Atthe cupola spout, it wes necessary to weigh
the iron end determine ite temperature. The weighing
wee first done on a platform scale, the iron being Lifted
in the bull-ladle each time and set upon the scele to be
weighed by means of the crane. The tare weight of the
ladle was aleo taken. ithe time taken by the method made
it very objectionable to the proper handling of the cupola
iron, and a spring scale, which was suspended from the
Orane, wae subdatituted and eliminated any neceasity for
cnanging the position of the bull-ladie. In this scale, the
spring elongation wae connected by a wire go se to turn a
pointer on e circular scale. Tine apparatus was found to
weigh within one or two pounds of correct weight, and its
capacity was about 2,000 pounds.

the messurement of the temperature of the molten
iron was to have been accomplished by means of a special
pyrometer, heving a platinum rhodium couple. The main gif-
ficulty in the use of this pyrometer wee the fact that it
took about fifteen minutes to heat through the fire clay
tube, which surrounded the couple, and thie made the read-
ings somewhat douttful. Again, the olay tube wae broken
twice and when the pyrometer was first used the instrument
had a short oircuit and the resdings of the voltmeter were
too low. tne readings, which the instrument registered,
were aleo hard to uee because of the fact that tne specific
heat of the molten iron was not accurately known, and could

not be determined by the apparatus at hand.
whe

Analysis: In tne analyeais of the v:. rious iron
of the coke and stack gas, the work was done in the Chemia-
try Building, uncer the direction of hr. “. F. ‘Yood, «2 at
firet planned, tne anslysis of tne irons used was to i:ve
been made for each test, but the difficulties encountered
msde it impossible to analyse more than four esrmles of iron
in the time given. ‘Zhe results, wiich were Tinally secured,
were only f:ir as to accuracy and would never hate teen
gotten except for the kind assistance of ir. Yorker, the
Chemiet of the Reo Kotor Car Company. Some trouble waa alse
encountered, due to poor chemicals, and it wae necesriry to
secure some chemicals at the eo hotor Car Company. In riak-
ing determinations, the methods enployed were subetantially
those employed by the U. 5S, Tteel Corporation, as describved
in the *Transactions of the American Inatitute of Lining
Engineers",

Determinations of Total Carbon. fiee illustration).

Thies wap done by direct combustion in a current of oxycen at
1000°%C, the carbon-dicxide being absorbed in a special soda
lime and the change in weight teing taken as due to the
carbon-dioxide absorbed. The combustion takes place in a
fused quarts tube, 24.inehes long, which is heated by a
Hoskins £lectric Furance, The tube wsed wee only one-half
inch in diameter, which is ruther small, a 7/6 inch tube
veing recommended, The sample wus placed in a porcelain

voat
boat about 1/4 inch wide by 2; inches long. inhie size of ree
-5=

rather small for a one grain sample, and the result of
using it wasfrequent trouble with spilling of the oxide
and breaking of the doat. The oxygen was sent through
the train from a gasometer at the rate of about 500 cc.
per minute. The oxygen was first purified of CO2 and
moisture by passing through KOH, Ca e12 and Soda lime,

(Na OH; Cao). It then passed through a Meroury seal and
ever the sample. The products of combustion then passed
through metallis sino and phosphoric anhydride, (P205),
which were for the purpose of removing any acids or moist-
ure present after combustion. Thence the gases passed to
the absorption apparatus which consiated of a number of
layers of a preparation of Na OH, Ca(0OH)5 and H20 from the
J. T. Baker Chemical Company. In the same tube,(as used
at the Reo Xotor Car Company), was placed some P205 to ab-
sorb any moisture which might be formed upon the absorption
ef C02. The absorption tube was weighed before and after
each combustion.

The gae was next passed through a wash bottle
filled with KOH, which gave a means of telling how fast the
oxygen was passing over, and whether any leaks were present.
The actual cembustion was found to take about two or three
minutes, ahd the oxygen was passed for about five minutes
before and about ten minutes after combustion. It can be
seen that once this apparatus has been set up it ought to
be possible to run all the determinations wanted in about

one afternoon. Nevdrtheless, it took about 140 hours of
be

work to make four dcteruinctions cra to cet them to cheek,
This wos due to the necessity of msking substantial chonzves
in the set-up in order to secure a lecrger supply of oxygen
snd the operation of the furnace at too low a tei.perature,
whenit wss impossitie to ¢et the iron to burn properly.

Betermin stions of maganere and sulphur vere made
as Outiined by the U. &. Steel Corporation in the *Trans-.
action of the A. 1. :. s- All Other determinstions vere
mede ag outlined in Blair's “Chemical Analysis of Iron und
Steel.

The following references were ured tus preliminary
reeding anc were constantly referred to in muking calculae
tions:

"Chemical Analysia of Iron ond Steel", «A. A. Blair,
“kethods of the U. S. Steel Corroration for the
Sanpling and Analyaie ef Pig iron*. J. i. Camp. A. 1. 1. &,
“,etallurgical Calculations”. Farts 1 and Il.
J. %“. Rbohards.
*Fuel sufficiency in the Cupola ¥Yurnace",
Jo. J. Porter, A. Le te be
“Foundry Cupola Gores and Tenperstures“*, Bul. 54,
Je O- Fureau of kines,
*“tetallurgy of Lion sand cteel". 56, Stoughton.
“RKelting Iron in Cupola furnace."
Dr. R. koldenke, A. 1. ie ie
“jransactions Of A.erican Foundrymen's Asesooi: tion -

1908,
"Transactions of American Institute of kining
Engineere*,. Vol. 36, Face 454.

"Principles of Letallurgy". C. H. Fulton.
-B-
&2THODS GF CALCULATION,

The first step in calculating the heet balance is
to mae a materials balance. This is done first ty comput-
ing the weight of each element charged per thousand pounds
of iron charged. The analysis of iron, coke ard the
humidity of the blast are used to determine this. Yhe iron
delivered :t the spout per one thousand pounds charged is
calculated and from its analysis the elements delivered here
are determined. The weight going into the blunt and slag is
determined by difference, all Fe, Si and ku charged which
does not go into the molten iron is ansumed to go into the
Slac as oxidea, and the S ahd P, and ash in the coke into
the stackigases.

The percent of carbon burned to COo and the per
cent burned to COQ is determined by the analysis of the stack
gases, and from it the weight of GO and 605 is determined.

From the meterials balance sheet the sources of
heat, and the heat used and lost are determined. The same
sources of heat are sensible heat in the materials charged,
the heat formation of iron, slag, ctc., and the heat of
combustion of fuel charged.

fne sensible heat of a substance ia the neat wnich
is necessary to raise it feom sero degrees F¥, to the temper-
ature at which it is charged.

The heat of formation of substance is the heat

which is liberated by oxidizatien.
-Je

20@ heat of combustion of fuel is taken heat
whic:. is liberated shen the fuel is oaspletely burned.

ane heat used and loat is the sum of tie neat used
in melting the iron, the heat used in melting sla.;, the
heat necessary to hest up cupola lining, and the heet lost
in the stack gases in unburned CO, in superheating moisture,
and in racisastion,

The heat used in melting iron and elag ia calcue
lated in three parte: (1) the heat to heat iron to aelting
point; (2) the heat of fusion, and (3) the heat ueed to
hest the liquid.

she heat to he:t up the cupola lining ie deterwzined
frou the weight, eapecifia heat, and mean temperature of the
lining.

The heat lost in the sensible heet in the stack gases
is determined from the weicht of stack gases, ani their
speoifie heat and temperature,

tne potential hest in unburned CO is determined from
the weight of CO gas and the potential heat per pound ,

the heat necesssry to supernent moieture in deter-

mined from tne temperature ond the menun specific heat.
Table of values of heat in computations in B. t. u. per

pounde

lie>st of fusion of Blin ee pepe esvececcosereseecene 100,0

Heet
Hest
Heui
ews

Hest

Of TusioOn of ArONecaccncccccscsccovesevecscos 4144
of burning LTONsacecccvcvsscsscevevessecssees Li ed
of burning BLLICONs ceca cevcccvesconservcecseelausted

Or nur’ing ILM EONE SS pe eoevecvrecvrevreseseeser «17520

OT VULrnNdNg COkeecccvevecccccccccsvrevesesseelerlI V00

heatcf burni ng POON, cavcccccvcvccvecccccsossessee (20009

nest

of burning COcccccccecscecccsccsecsescesessese 437060

Table of Secifie Heute,

COKC. cocscccessescccccsssccccerssscseccccecesees Uelfi
Tron (GOLA d) cecrccceccrccccccccccccsvccecesesens Delt
Tron (Olen) occccccccccccccnvescccccnccseseccces 024
ELHPbecccccvccvcccscsccencsccccssesssccsccecsesees§ Oec 37

CABE}B ewe cccercne res cee see erence eeeeesncseseveecses 0.°72
-dle
Balance Sheet per 1000 bb. of iron charged.

 

TEST HO. 1.

 

 

 

Ce 86 ©8 CO 06 28@ S60 Sf ©8 O88 88 £@ ce Of £8 eo 0©8@ ©8 ©86 ©8 80 of ef 8@ 6e@ 28 ©8 c@ 88 88 08 98 €8 08 GH of SH ce SO £e 8O 68 C8 o8 C8

e
é
e
6
e
®
®
6
e
e

4.220:
22.700
1.603
Q
083

374.000
65.3100
121.460

Gases

© @26¢ 60 ce 88 © 280 6£80 68 8 BO FO @286 ©8 Be *8 8 ce 420 98 £80 £0 CO 20 20©0 *8 oe @©8 ©8 20 ©€0@ *8 ©8 c8@ SO OF «¢ -@ @©@ 26 ©8 ee @¢8 20 86 FO OC os OO

s So © a
$0208 0 St za OM

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0
Ash

96
2)

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3

¥e0:60.20

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3
$

3

Slag

eC@ coe FO ce ve ©@ of £8 60 £8 28 «oo C8 86 C8 FO C8 ce FO 6¢0 CO 08 08 Ce eof co of

oe
S

al

8 60 2c0§ ©8@ ©€8@ ©6868 ©0© o@ ©8 8 4680 08 ©8 6 «mH 8©8@ 9©@ 28 vo 6 6 26 C8 CO SO 68 860 COO 68 28 26 88 oo ©8 8©89 £6 8S 60 268 ©8 oe FO C8 6S 88 08 OF GO 88 FOR Ce 280

ex & &

882.784

3 33.400

: 15.800:
3.6
4.6
0.69

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3

Castings

Fe

506.130: C

:
é

22.7003

19.250:
2.390

3

Ze 540: ¥n

3.200: 8

Se 28 e888 CO

e
¢

2.330:

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6
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1970.000:

450.000:

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of 3)
Oo

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$

19.300: P

i
3

9.920: 8i

®
®
nas
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00

52
1510.000:
10.0
3 3121.400:

o 9
~N

‘Oo

e e e
Or om

458
423
151 .400
124.767:

$

SoraplIron: 541.500

e282 @€0 @€@ 8©8 2868 ©@ 08 88 C8 oe SS oe F@ of eo e@ 8&0 ce 06 @8 FO ce C8 ce e288 CO Oe CO 48 O88 Ce 86 80 Fe 8 oO F6 C8 O88 86 O88 CO CO

$

Charges

 

 

Pig Iron

Total
Fe
8i
Mu

Total C
P
S
Fe
Bi
tw

Total C
P
8

Coke
C
8
Ash
H20
Blast
02
W2
_20
Total
 

 
“l2@

Balance Sheet per 1000 lbs. of iron cherged.

Tssv NO, 2.

 

Casee

Slag, 3

Custings 3

3

Cuarges

*¢s

ae

 

e@ ©@ *¢@ e@ #6 #0 26 coe «Ss *@ C8 CO

9 @۩0@ *@ e868 C8 2.@ OB *@ 80 eo SO CO

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e©68 6@ e@ *8 68 ©8 ce ve 8&0 Of o® 8

$
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Balance sheet ver 1000 1b. of iron charged,

 

ACG cared,

 

 

Charges ‘ Caetings : BL Gucee

3 ; 3 : 3 aT “

Total ; : : : : : : 3
rig Iron .: 235.000 : 3 . ! 2. :
ye § e17.101 3 3 é 3 ; 3 :
S3 ; 4.941 3 : : é 3 : ;
Ln 2 1.860 3 ; ; . fi ;

C $ 9-630 3 3 $3 i 3 }

P S Lee 30 3 é ’ : : :

8 : 0,038 3 : : 3 6024 5 «3003

Sere piron._765,000_ :

ve
od
iin

C

Total

3.715.118 ic
3) 614,000

s ©93.066:¥eo
i 32.000:5102;
$ 13.000: nO

3 2.9750:0 &

12.700:CO 3

 

$ 3.606 jun 3 36320. 3 pS

$ 27.200 iP 3 4.180: 3 $8

¢ 6 4.500 35 3 0.630; 3 i 3

7 a. Se ; : : :

> 3.73.000 : : : : :

: : : ; 2 8

3 139.900 3 3 3 : s 3

t 2,660 3 3 3 ; food,

: 28.600 3 3 : 3 thehs 2c
+1840 3 3 3 3 $H203
31960.000 : : : : : 3

: : $ : $ $f

: 13.2100 : t : 3 311203 13
3 449.000 3 3 3 : > 3
22497-2990 5 3. : 5 ste 314

; : : a ; +
33133.000 : 3 945-190: 365.7003

3&:,0003
G7 «003

95.4253

°
@

8

®

32121.9653
-14«
Balance gsheet per 1000 lb, of iron chsrged,

4.

T2cT NO,

 

 

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64.5 1948. 50

949.5

2972.90

total
“15

Balance sheet per 1000 lb. of iren charged.

TEST NO. 5.

28 €¢08 o@ 88 £9 ce O88 C8 Of

3

%

 

Cases

é

;Gastinge 3 Slag

Charges

é
3

Charges

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Total
-17-

Heat Balance for Test No. 6.

1. Heat of combustion of fuel. - Total heat evolved =
12130 x 1b. of coke burned + 7,200 x 1b. of wood burned.
Hence B. t. ue per pound of iron charged =
12130 x 0.187 + 7,200 x 0.0215 # 2424,
2 Oxidation of iron to FeO. - Kelting loss in iron =
6.04%. Then B. t. u. per poand of iron charged =
0.0604 x 2112 = 127.0.
3- Oxidation of silicon te 8i0o. - Melting loss in
silicon = 0.316%. Then B. t. u. per 1b. of iron charged =
0.00316 x 12600 = 40.0
4. Oxidation of manganese to MnO. - Kelting loss in
manganese = 0.229%. Then Be. te ue per lb. Of iron charged =
QO. 00229 x 2975 = 6.8.
5. Sensible heat in coke. - B. t. u.pj per lb. of iron
charged = 0.187x68x0.16 per: 1b.of iron charged = 2.03

6. Senebble heat in iron. - B. t. u. per 1b. of iron
charged = 1 x 68 x 0.12 = 8.16.

 

7° Sensible heat in blast. -
_ —» 460 +
V= 66.2 ny ( 40-*8)8 9

V = velocity of air in feet per second.

hy = velocity heat in inches of water.

t = temperature of entering air.

 
Then V = 66.2 (1.63)! ( 330) 0.92.

= 66.2 x 1.28 x 1.005 x 0.92 = 78.4.

Area of pipe = 48.7 sq. inches.

78.4 x 48.7 x12 x 6

= 1590 ou. feet per minute.
1728

Volume =

Time of test - 64 minutes.
1590 x 64 = 102,000 cubic feet of air used during test.
Relative humidity = 80.6

Pounde of moisture per cubic feet of air equals 0.00086.

. 244% 14,85 x 102,000 _ 20 lbs.
Total webght of air used = 53.34 x 528 77 8

Weight of moisture in air = 0.00086 x 102,000 = 88 lbs.
Weight of dry air used = 7720 - 8&8 = 7632 lbs.
B. t ue per ib. of iron charged =

7632 + 3856 x 68 x 0.237 = 32.0
8. Sensible heat in moisture of blast. - Pounds of
moisture per lb. of iron charged = 0.023.

Total heat = 1089.4 B. t. u. per 1b,

Then B. t. ue. per lb. of iron charged =

0.023 x 1089.4 = 25.0

9. Heat and formation of slag. = This is a matter of
some uncertainty, but is of minor importance. Theheat of
formation of Ca0 + Sido is 278 B. t. u. per 1b., and if
FeO + 8109 is B. t. uw. per 1b. and if we assume that the
slag consists of equal parts of each and that we have
0.089 1b. of slag made per 1b. of iron charged, then the
heat of formation of the slag is in B. t. us. per lb. of iron
charged 0.089 x 200 = 17.8.
1a. Heat in molten iron, - Specific heat of solid cast

iron = 0.12
Specific heat of molten iron = 0.24.

Kelting point 1950F.

Tempersture Of iron iseuing from spout 2138 °r,

B. t. up. per lb. of iron charged =

0.93 (1950 x 0.12 + 41.4 + 188 x 0.24) = 298.
2a. Heat in molten slag. - B. t. up. per lb. of slag =
1 x(t x (0.17 + 0.0000t) + latent heat of fusion + (t'-t)
0.35], where t = melting point of slag.or say 2000°F., and
t’ = the temperature at which it issues from the cupola, or
say 2250°F, ro

Henoe EB. te. up’ per lb. of iron charged =
0.069 (2000 x 0.2 +160 + 250 x 0.35) = 0.089 x 747.5=66.5
3a. Heat to evaporate moisture in cok@-- B, t. u. per
1b. of iron charged = 0.187 x 0.0106 x 970 = 1.92.
4a. Heat stored up in lining. - The weight of the lin-
ing below the charging door figures out to approximately
5410 lbs. Estimating ites averaze temperature to be 1000°F.,

C4
the B. §. ue. per lb. of iron charged = <ae0 * 1000 &

| 54 _
(0.193 + 0.000043 x 1000) = sEhe x 1000 x 0.234 = 329.0.

Sa. Heat to superheat steam in the moisture. FE. t. u.
per 1b.of iron charged = 25.0 ¢ (0.49 x 1764 x 0.023) =
25.0 + 19.9 a 44.9
 

 

 

e2Qe@

6a, Heot nsenasible in (seee. - Averace specific hest =
0023 ¢ 0,000023t = 0.23 ¢ (0.000023 x 1822) = 0.23 + 0.042 =
0.272. tnen B. t. ue per 1b. Of iron charged =

2.1478 x 1822 x 0.272 = 1065.0.
7a. Heit potential in gases. - B, te. up per lb. of iron
charged = 0,0'99 x 4370 = 393.0.
Ga, Roediation and error. - Thie smount ia found by dife-
ference tO be B, t. up. per lb. of iron charged,

summarising these iteme, «ce cet tne following heat

valance exprese in Fr. t. ue. per lb. of iron charged:

Sources of neat Heat Uped anu Tort.
1. Conbuetion Of fuel 2424.00i1la. In molten iron 253.00
2. Cvidation of iron 127.00:28. . ° elas 66.50
36 . ° Si 40.00:38. To evaporate moisture 1.92
he * ® kn é.80:4e. To hest up lining 129 00
5. Sensible in coke 2.03:5a. To esuperhest vapor 44,90
6, e 9 Pe 8 .16:6e. Sensible in gases 1065.00
Ze . " dilsst 32.00:78. Potential * * 393.C0
8, . * moi sture 25,00:Sa. Radittion and error 464,47

3
9. Formstion of slag 17.89:

 
 

1.
2.
3.
4.
Se
6.
7.

8.
9.

-21-

TEST NO, l.

 

Heat Balance Per Pound of Iron Charged.

Sources of Heat

Combustion of fuel 2150.00:1la.

Oxidation of ira 98, 60:28,

° Cf Sstlicon 47.50130.

* & Lv 7.40:4a,

Sensible in coke 1.12:58.

° * iron 5. 56:60.

. * bdiast 21.50: 78.

e * moi sture 10379: Ba.
Formation of slag __8, 63:
2341.10

Heat Pslance Per Pound of Iron
Sources of Heat

Combuntion of fuel 2221.60:la.

Oxidation of iron = €7. 50:2a.
" cof 3i 26.00: 3a.
" " rn 7.30: 48.

Sensible in coke 1.10: 5a.
* * iron 5.20.68.
° * direst 21 40:78.
° * moisture 8.60:8a.

Yormation of sl s¢ 8.20:

2386.90

Heat Used and Loat.

In molten iron 426.00
ad ° elag °° 3.30
To exaporate H20 1.55

To heat up lining 380.00
To superheat vapor 16, 6
Sensible in gases 682.00
Potential in gases 285.00
Radiation and errors96.65
2341.10

Cha rged.

Heat Used and Lost.

In molten iron 22 7.00

2 8 plang 50.80
TO ev&porate H20 1.90
To hest up lining 460.00
To superheat vapor 13.90
Senrible in cases 634.00
Potential in gases 263.00

Radiation and error 536.30 |

 

2 386.90
le
2.

3.
4.

De
6.

Ve

9.

 

226

TiGT NO. 3.

Heat Balance Per Pound of Iron Charged.

Sources of Heat
Combustion of fuel
Oxidation °* iron
a * gi
° * kn

Sensible in coke

e * iron
8 * piast
e © moi eture

2198.80:1a.
88.60 ie.
75.90 3a.
6.36 ide.
1.64 é50
7.08368.
27.2017m.
14.20:88.

3
Yormstion of sbag 2394!

2426.82

TsoTt NO. 4,

Heat Used and Loet

In molten iron

e n slag
T6 evaporate H20
To heat up lining
To superheat vapor
Sensible in gases
Potential in gases

Bediation and error

Heat Balance Per Pound of Iron Cnarged

' Sourcer of Heat

Combustion of fuel 2183.20:1a.
3

Oxidation of iron
@ @ 8i
@ @ hin

Sensible in coke
° °* iron
« *" blast

ad °* snoi sture

92.00:2a.
28,40:38.
4.80:4a,
2.10:5a.
9.47168.
33.20:78,

28.40:8a.
3

Vormation of slag 7280:

2389.40

Heat Used and Lost

In molten iron

° ® slag
To evaporate H20
To heat up lining
To superheat vapor
Sensible in gases
Potential in *°

Badix tion and error

 

 

 

427.00
49.10
1.79
281.00
22.80
780.00
428.00

437.13

 

2426.82

527 - 50
48.30
2.00
272.00
46.50
715.00
314.00
564.10

 

2389.40
1.
2.
3.
4.
De
6.
7.
8.
96

-23-
Tost NO, 5,
Heat Balance Per Pound of Iron
Sources of Heat

Combustion of fuel 2377.00:1la.

Oxidation of iron  110.00:2a,

e ° Sd 32420138.

° * kn 5.80:40

Senrible in coke 2420154.

° © iron 0,00:6a.

. "* Blast 39.40:78.

° * soi sture 32.20:68,
Fornati n of slag 9.30:
2617.10

TEST NO. 6,
Hest Balanced Per Pound of Iron
Sourees of Heat
Combustion of fuel 2424,00:1a,.
127.0032a,
oiliecon 40.00: 13a.

Oxidation of iron

« of

* 8 xn 6,80:4a,

Sensible in coke 2.03:5a.

. " iron 8.16260.

. * Ddiast 32.00: 78.

. * moisture 25.00:8a.
Formation of slag 17.80:
2682.79

Charged.

Heat Used and Lost

In molten iron 425.00

° * slag 57.50
To evaporate H20 2.30
To neat up lining 329.00
To euperheat vapor 53.20
Sensible in cases 942,00
Potential “ * 635.00

Radiation end error 173.10

2617.10

Charged.

Yeat Used and Lost

In molten iren 298.00
. . slag 66.50
To evaporate H20 1.92
To heat up lining 329.00
To superheat vapor 44.90
Sensible in gases 1065.00
Potential in gases 393.00

K:diation and error 484,47

2682.79
General Deta on M, A, C, Cupola.

1. Diameter of cupola, inside 24"

2. Diometer of copola, outside 36"

3. Height of tuyeres, above bottom 10°

4. Height of charging door above tuysres 93°

5. Ratio- 451 3.88

6. Number of tuyeraes 6

7. Size of tuyeres = Vertical X horizontal 6" x 5*
8. Aree of tuyeres 180 sq. in.
9. Ratio of cupole area to tuyeres area 2.5

10. Diameter cf blast pipe 7.87%
ll. Area of dlast pipe 48.7 sq.in.

12. Fan type and epeed - Sturtevant Blower Fan 2800 R. P. 4.
13. Clee of work done - Job castings
14. Find of fuel used - Coke.
 

 

CUPOLA TST DATA - &. A. C. CUPOLA

1. Test numer 1 2 3 4 5 6
2. Blast pressure
in cupola 6.75 7 6.75
3. Cu.ft. air ine 1263 1392 1620 1612 1565 1590
put min.
4. Avg. humidity
of air 78 70 62 66 66 80
5. Temp. of enter-
ing air F. 43 59 79 75 68
6. Temp. gases at |
charging door ¥. 1250 1100 1400 1110 1472 1238
7. KR. P. Me. of fan 2440 # £2440 2760 2690 2690 £2630
8. Horse-power in-
put, fan. 507250 45687 S682 462 G00
9. Wt. fuel on bed-
lbs. 300 300 360 360 360 360
10. Wt. of iron on ved
lbs 562 555 654 650 550 550
ll. Wt. of flux : 10 10 10
12. Wt. of fuel in
charge eubse- 60 60 60 60 60 60
quent to beds
13. Wt. iron in
charges subse- 550 550 550 550 550 550
quent to beds
14. Total wt. of 600 590 780 780 720 720
fuel “108.
15. Total wt. of 3323 2755 4506 4650 3850 3850

iren-lbs.

16. Ratio of fuel
to iron bed 1:1,87 1:1,85 1:1,81 1:1.81 1:31.15 1:1.5
Ratio of fuel

to iron

17.
1:5.5 1:3:5.2 1:35.75 135.95 1:55.35 1:5. 35
 

 

 

 

=-26e

Cupola Teast Data - Continued.

16.

19.

20.

21.

Chemical Changes of Iron Charged.

‘iest number 1 3: 2
Per cent losa in ¥e 5.04 3 4.45
Per cent loss in 8i 19.2 Li
Per cent loses inkn 40,3 , 39.7
Per cent loss in C 13.4 : 10
Per cent loss in P 16.8 : 14.9

Percent gain in 8 43.8

Time vefore
iron comes after 15 15
biast is on

Lbs.iron melted 60.4 £465,.8
per mimte

Los. iron melt-

ed per min. per 19.2 21
eq. ft. cupola

area

Temp. of iron at
epbut ? ?

45.8

ee@ eo Se oo Ou O88 Ge Ge 68

@e ge @e Ge ve

18

71

22.6

4.19

31.4
39-2
16.2
27
1.

Os OC O20 Ge eo O28 Se

@s ee 08 88 Se @e Ge

>

4.68

12.2
30.8

5.4
15.6

fe

7

ee Ge os Se oe os os es 80 oe 02 oe PS ce

2
526

139

Las
>

8.3
15.4
12.9

Se @8 ee eo 8060 00 of 80 @e O88

@e @2 @s8 8°29

23

67.4

21.4

2138

.

16.8
38.6
9.2

14.9
18.4
 

 

in ¢00d cupola practice, cre firet iron should come
from seven to ten mi nutes after the blast is put on. ine
aver:z.e tine fer the firet iron in our teste was eignteen
minutes. This le-ds us to believe that teo much coke is
put on the bed. 4xanples of modern cupola practice confirms
this rvtstenent. Our iron melted per pound of coke is leer

them in comparative oupola practice, Thie makee our heat

loar by radiation and error hich.

vtandard practice mtates that aout one tnousand
cubic feet of air should be used per minute. We used about
1800 cubic feet per minute. By reducing the bed, we could

reduce the amount of air used,

¥rom our total hest balance, it is evident that
the crest souree of wasted hzat in the cupola is in the
eacaring grg9es. ine tempevature of the top crees denends
on tiie maount of heat absorbed by the stack in proportion te
the tots] amount generated. ore nest ie generated when C
is burned to CO.

gae rapid rate of blowing that yas necesassry to the
formation ef CO>o increasc@ the velocity of the garee and
gives lese opportunity for the sbeerption of heat by the
etack.

Ae a final conelusion, we eussest that the fuel bed
. be cut down, and coneequently the Llast prersure. tne peek-
holes ehould be repaired #0 «8 to be air thiht. If tie ie

done, the fsn enn be run slower, %e #196 au; eat that in
 

 

- 28.

charging, the cupola should ve kept full to the chereing door,
This will eliminate a large part of the waste heat in top
gxees. Since a high sulfur coke is used, more limestone

should be charged to reduce the aulfur in the castings.
 
 
i ian oe : Se ‘ , vez 4 B a Ae

~ z S Spy : & *.
‘ . _— le —— ocr ' Las , Bn

“MECHANICAL ENGINEERING LABORATC Me

MICH

!

»
v2

4

as AD A; ESCOT-7~
py. *
coke

R557 14.6 .@
IL+F 18
Vie) ona

Ihe 6B

$
JF

a

 
ad

S

a

a)

nh

=

oe

Fortin ME. 07-1 iy SF a

Sheet No.

MECHANICAL: ENGINEERING LABORATORY
MICHIGAN AGRICULTURAL COLLEGE

Runuing Loot keot- CS ARn. SP ey ene 5 Pr
Pet ee wy eae Les

bore @tre tats Assistants

| A fh Grace tt |
! y " Saetete ee - , pal the. 2Ei0/F

Observers

2.53 463 as7 206
A255 460 310 (so
2,:574€0 310 190
BOL 4AWIS 360 (35
3.02 540 4]0 790
re so. a ae ee Ee mee Se
3.908 605 282 3223
cA ee ~ 5 “ho ay a i ae
SIS 610 275 FIS
3.290587 275 312
3-232 G00 354 246
3.25 650 3490 Flo
3-279 626 FJi2 313
332-635 327 30%
3.37 GIS 264 35!
3-403595 29795 320
34559 S 270 BIS
3.59 SoS 370 [35

ye we

PRaak on 2,34 10” on Files.
SOO cays ie ee

Remarks:
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Sire Laas Oem TLD | Sheet No

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