Now-a-days a large variety of heating techniques/furnaces are available. There may be many method for supplying heat to the work but heat is produced either by combustion of fuel or electric resistance heating. Taking into consideration the effect of cost, safety, simplicity and ease of construction we are going for an electrical resistance heating furnace with indirect heating provisions. The stir casting furnace has two main parts that enable to perform all its operations, they are: Furnace Elements and Control Panel. This paper shows the design and fabrication of stir-casting furnace and aluminium melted and casted to form.
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Innovative Systems Design and Engineering
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This research work focuses on the design of a 50-kilogram capacity Cast-iron crucible furnace that is fired with diesel fuel. The furnace drum has an overall combustion capacity of 0.1404m 3. It is fitted with a chimney to allow for the easy escape of combustion gases. The air blower discharge air into the furnace at the rate of 0.3m 3 /s with an air/fuel ratio of 400:1. The cast-iron crucible furnace is designed to consume 4 gallons of diesel fuel with a rating of 139000kj/gallon which is required to completely melt 50-kilogram of cast iron over a period of 90min. The designed operation temperature range of the cast–iron crucible furnace is 1300 0 C to 1400 0 C. The cost of the cast-iron crucible furnace is three hundred and forty-eight thousand naira (N348, 000.00).
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International Journal Of Scientific Advances
The Cupola Furnace Capacity of 450 kilograms per hour was designed and fabricated using locally sourced raw materials which include pig irons, crop ends and foundry shop returns, and ferroalloys for the production of quality cast iron which depends on the customer’s demand. Metallurgical coke is the main fuel source employed for the production processes. The design parameters were analyzed and the metallic shells were then fabricated into four sections to allow proper lining. A mild 5 mm thick steel sheet was collected, marked out according to the required specification. slit and formed into cylindrical shapes. The sections were coupled and joined together through a welding process. Sodium silicate was used as a binder to make them bondable to the interior sections, the internal configurations were first lined with asbestos sheets measured 5 mm thick. with a less dense insulating refractory material. Fireclay refractory bricks were used for furnishing as they directly interfaced wit.
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International Journal for Research in Applied Science and Engineering Technology -IJRASET
The research work presents the design concept and production of a portable Bale-out cast iron crucible furnace that is fired with diesel fuel. Therefore, the work deals with the design, production and testing of oil fired crucible furnace using locally sourced materials. The components of the oil fired crucible furnace are; furnace drum, crucible pot, brick lining, plinth, furnace cover, furnace cover opening and closing mechanism, blower, hose, air valve, burner nozzle, diesel valve, diesel tank and tank stand. Design drawings were produced and mild steel sheet was used for the production of the furnace, while the other components needed for the design were selected based on functionality, durability, cost and local availability. Tests were performed to evaluate the performance of the furnace. The results showed that it took the furnace 15.67mins to completely melt 5kg of aluminum scrap at 651.67 o C with 0.93 litres of diesel and it took 73.33mins to completely melt 5kg of scrap cast iron at 1209.33 o C with 3.93 litres of diesel. The furnace overall cost of production is one hundred and ninety thousand seven hundred naira only (N190,700.00) which is lower than the conventional furnace which cost two hundred and ten thousand naira only(N210,000.00) and is suitable for both in the rural and urban areas. The furnace is environmental friendly without health hazard to the workers and can be moved from one place to another unlike the local one. I. INTRODUCTION A furnace is an essential equipment or device in which the chemical energy of a fuel or electrical energy is converted into heat that is then used to raise the temperatures of materials [1]. Furnaces operating at low temperatures are often called ovens depending on their purposes and there are other furnace used at higher temperatures for various materials and purposes [1]. Furnace is used for high temperature heating to melt metals for casting or heat materials to change their shape (eg, forging, rolling) or properties (heat treatment) [2]. Since exhaust gases from the fuel comes in contact with the surface of materials, then the type of fuel used is important because some materials will not tolerate sulphur in the fuel. Solid fuels generate particulate matter [2], which will interfere the material placed inside the furnace. For this reason [2], most furnaces use liquid fuel, gaseous fuel or electricity as energy input. Furnace ideally should heat as much of material as possible to a uniform temperature with the least possible fuel and labour. The key to efficient furnace operation lies in complete combustion of fuel with minimum excess air. On a general note, furnace is also employed in the heat treatment of metals in order to influence their mechanical and physical properties. A crucible is a refractory container which can withstand temperature high enough to melt or otherwise alter its contents [3]. A crucible furnace is among the oldest and simplest furnaces used in the foundry; it is a piece of equipment used in foundry industry for melting metals for casting metallic wares such as machines, machine parts and other related engineering materials. It is mostly used in small foundries or for specialty alloy lines. The crucible or refractory container is heated in a furnace, typically fired with natural gas or liquid propane, although coke, charcoal, oil, or electricity can be used [4]. A cast iron crucible furnace is therefore one meant for melting and casting of cast-iron products [4]. The importance of the cast iron crucible furnace to the foundry industry as it affects the industrial and technological development of any nation cannot be overemphasized, since many machine components are made of cast iron. The furnace is mounted on two pedestals above the floor level for planning the molten metal. Oil and air are admitted with pressure through a nozzle [4]. The crucible is placed in the heating chamber and is heated by the flames. The furnace can be stopped whenever needed and temperature can be controlled easily. This gives lesser pollution. However, improvements in efficiencies have been brought about by methods such as pre-heating of stock, preheating of combustor air and other waste heat recovery system [4]. Oil fired furnace mostly use furnace oil, especially for preheating and heat treatment of materials. Therefore the aim of this work is to design and fabricate an oil fired bale-out cast iron crucible furnace using locally available materials that is portable, safe, economical and affordable to small and medium scale foundry shops.
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