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A furnace is a machine used to melt the metals . There are different types of technologies which every furnaces uses them to melt different kinds of metals . If you are someone working in foundry field , it is essential for you to have knowledge about melting furnace technologie .
In ancient times when human discovered fire and understood how to light a fire ; s/he had not so much information about it . S/he did not even know how to cook her/his food .
By passage of the time, as s/he grew , understood founds out how fire is important and how it can impress her/his life .
The modern human knows its importance . If you are someone working in foundry field , it is essential for you to have knowledge about fire and melting furnace technologies though .
It would be so important for you and your business how melting furnaces work and how is the process and functionality of melting steel .
The turning point of foundry is furnaces and the turning point of each furnace is its melting liquid . Each furnace uses different methods to melt but the key for all of them is to utilize as little as fuel and having the same produced energy at the end .
A furnace is a machine used to melt the metals. There are different types of technologies which every furnaces uses to melt different kinds of metals . Some common types of melting furnaces are mentioned below :
As the foundry technologies are growing and as steel producers produce more steel , the induction forging furnaces are developing .
Induction furnace are electric machines that can melt the materials by sending currents to coil which has surrounded the furnace .
These furnaces having copper coils . Coppercoils flow the electric currents around the furnaces . The electric current produces more heat which causes the metals melt easily .
One more thing to know is that the water supply in this process makes it cool and prevents the coil itself melt .
Whatever goes into this process is exactly what comes back out ad there are no additional oxygen or other gases into the system . This means that these kind of furnaces can’tpurifysteel . These kind of furnaces are easy to manage & produce about 65 tons of steel once .
The only weak point is steam . Even a drop of water can cause explosions and damages for the alloys or thetools and workers .
Voltage of electricity can be low-frequency , middle-frequency or high frequency . Heat transition & conversion of electrical energy to heat is devided into canal furnaces & core free furnaces .
After the process is done , the molten materials will placed into the mold . Via the ladles , smaller portions of materials will bring out from the main furnace .
These tools (ladles ) will protect workers and keep them safe from flames & dangers .
After the end,the molten material will shape into desired shapes . Induction furnaces are one of the most common methods of melting todays .
Blast furnaces always used for metalworking with pressurized gases . This method usually pulls out iron from its ores .
From old times up to now the most basic form of furnaces are crucible furnaces . They could be used for high temperatures .
Low costs & easy operations made it the most popular method of melting ores in little or big factories . In these furnaces the temperature forwards to the main part . Jewelry makers still use this method .
- Ability to melt different kinds of metals
- Fuel abundance ( oil, gasoline and …)
- Low creation costs
- Easy to work with furnaces
- Low loss of materials
- Low efficiency ( between 10 to 15 %)
- Low capacity
Cupola furnaces are the most common tools for melting cast iron . The 2nd rate to form cast iron is made of these furnaces . These type of furnaces were created in China for the first time in 221-403 BC .
Cupola furnaces have simple mechanism and they are mostly used to melt scraps . The mechanism of these furnaces have so much similarities with blast furnaces . But their difference is that blast furnaces are utilized formineral iron ores . Cupola furnaces have different sizes .
Between 100kg to hundreds of tones they can melt metals .
Electric arc furnaces (EAF) include a main big shallow pond with a surface of refractory acid upon the melting bed .
When the furnace charge with scraps ,the electric currents starts . Then the melting begins. Temperature increases to about 4100°c which scraps melt .
These kind of furnaces are used to create different kinds of metals such as steel and steel alloys . The key pointfor these furnaces is that they can createlow-carbonsteels .
Iran is one of the most important countries using electric arc furnaces .
This technology used in some countries like China , Russia , America , Brazil and South Africa .
Electric arc furnaces can createsiliconin high temperatures .
Electric arc furnaces have some applications :
●Creation of different grades of steel
●Creation of different grades of rods with high quality in automobile and oil industries
●The common source of molten steel for mini rods or strips
Essential heat to charge the materials in Simens furnaces is provided via gases or solid fuels like charcoal or fluids .
Fuel burns into two containers which are located besides Martin furnaces . The fuel comes into the furnace . The two torches can not work at the same time but each of them work about 15 to 20 minutes and then the other one replaces .
When one of them is working the other one stops . These two flames work alternatively .
The materials used for Simens furnaces are :
Lime
Calcium fluoride
Bauxites
Broken bricks
Iron ores
Steel scraps
Cast iron
Flash furnaces are furnaces which has the direct contact between fuel and the materials . Heat brigns to the materials in 3 ways :Forwarding , Leading , Flashing . In other words flame currents upon the materials and byflashing the flame the melting does .
Flash furnaces(reflective furnaces)have two subcategories : Fixed – Turning .
Flash furnaces are used to melt non ironic metals and alloys . They used to melt cast iron with the capacity of 300kg .
Fuel for these furnaces could be liquid,gas or even solid . Capacity of these furnaces are between 15 to 75 tones but they have smaller sizes like 500kg capacity too . These furnaces are also used for keeping which has 90 tones capacity .
Important advantages of flash furnaces are :
●High capacity of molten materials
●High heat efficiency
●Equal spread of heat and cand chemicals (because of good mixture)
Ahan Pouya with more than a decade of best-selling experience, adheres to professional and ethical principles in the field of selling and buying at inside and outside the borders of Iran, helping you in the steel industry.
