Pouring furnace

Big moulds are not moved during eooling. The eooling time can be up to several days. 

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The Ca reduction of the fluoride can be scaled up into a semicontinuous process with a reduction and pouring furnace similar to that described by Carlson and Schmidt (l%la) for the preparation of Y metal (see fig. 2.3). Granular Ca is mixed with the YF3 and placed in both the hopper and the... 

Fig. 2.3. Reduction and pouring furnace for semicontinuous preparation of Y metal (after Carlson...

Frequency Selection. When estabhshing the specifications for a coreless induction furnace, the material to be melted, the quantity of metal to be poured for each batch, and the quantity to be produced per hour must be considered simultaneously. Graphs have been developed that combine these factors with practical experience to indicate possible solutions for a specific requirement. 

High purity 75% ferrosihcon containing low aluminum and calcium can be used in continuously cast heats where nozzle blockage is a problem. In iron melting, this ahoy is desirable to minimize buildup on refractory faces in the furnace or on stopper rods or nozzles. Low aluminum ferroshicons can also help reduce hydrogen pin holes in castings poured in green-sand molds. 

Vacuum and Atmosphere Melting. A coreless high frequency induction furnace is enclosed in a container or tank which can be either evacuated or filled with a gaseous atmosphere of any desired composition or pressure. Provision is made for additions to the melt, and tilting the furnace to pour its contents into an ingot mold also enclosed in the tank or container without disturbing the vacuum or atmosphere in the tank (Fig. 2). 

When the furnace is tilted toward the charging floor, which is on a platform above ground level, soHd scrap is dumped by an overhead crane into the mouth of the furnace. Scrap can form up to 30% of the charge unless it is preheated, when up to 45% may be used. The crane then moves away from the furnace and another crane carries a transfer ladle of molten pig iron to the furnace and pours the molten pig iron on top of the scrap. 

Charcoal is produced commercially from primary wood-processing residues and low quaUty roundwood in either kilns or continuous furnaces. A kiln is used if the raw material is in the form of roundwood, sawmill slabs, or edgings. In the United States, most kilns are constmcted of poured concrete with a capacity of 40 to 100 cords of wood and operating on a 7- to 12-d cycle. Sawdust, shavings, or milled wood and bark are converted to charcoal in a continuous multiple-hearth furnace commonly referred to as a Herreshoff furnace. The capacity is usually at least 1 ton of charcoal per hour. The yield is - 25% by weight on a dry basis. 

The zinc is normally melted in a gas, oU, or coal-fired reverberatory furnace with a capacity up to 100 tons or in a low frequency induction furnace with a capacity of a few tons. The more highly aUoyed compositions are more effectively melted and mixed in low frequency induction furnaces. The furnace must be refractory-lined to eliminate iron pickup by the molten metal. The metal temperature is maintained below 500°C to minimize loss by oxidation. A ladle is used to transfer the metal for casting into molds the pouring temperature is usuaUy ca 440°C. Zinc scrap is not generaUy suitable for remelting because it may contain undesirable impurities. 

Steel mills Blast furnaces charging, pouring CO, fumes, smoke, particulates (dust) Good maintenance, seal leaks use of higher ratio of pelletized or sintered ore CO burned in waste-heat boilers, stoves, or coke ovens cyclone, scrubber, and baghouse... 

Electric steel furnaces charging, pouring, oxygen blow Fumes, smoke, particulates (dust), CO Segregating dirty scrap proper hooding, baghouses or electrostatic precipitator... 

Alloys of nonferrous metals, primarily the brasses (copper and zinc) and the bronzes (copper and tin), can cause an air pollution problem during melting and casting. The type and degree of emissions depend on the furnace and the alloy. Control systems consist of hoods over the furnaces and pouring stahons to collect the hot gases, ducts and fans, and baghouses or ESPs. 

After the steel is tapped from the furnace, it is poured into ingots or continuously cast into slabs or billets. Many metallurgical processes are... 

Increasingly today, steels after they have been tapped (poured) from the furnace undergo a further stage of processing called secondary steelmaking before the steel is cast. This applies to both the basic oxygen process route and to the electric arc furnace route. 

The iron formed in a blast furnace, called pig iron, contains impurities that make the metal brittle. These include phosphorus and silicon from silicate and phosphate minerals that contaminated the original ore, as well as carbon and sulfur from the coke. This iron is refined in a converter furnace. Here, a stream of O2 gas blows through molten impure iron. Oxygen reacts with the nonmetal impurities, converting them to oxides. As in the blast furnace, CaO is added to convert Si02 into liquid calcium silicate, in which the other oxides dissolve. The molten iron is analyzed at intervals until its impurities have been reduced to satisfactory levels. Then the liquid metal, now in the form called steel, is poured from the converter and allowed to solidify. 

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