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WHITING

useful

informationfor

foundrymen

METALLURGICALEQUIPMENT

SYSTEMS



A complete lineof

Ferrous Melting Equipment

With Materialand

Hot Metal Handling EquipmentEngineered for the job.

Copyright 2004, by Whiting Equipment Canada Inc., Welland, Ontario, L3B 5P4



The information herein is revised periodically to include themost current practical data useful to the people in the

Metallurgical Industry. Data is included on Induction Furnaces

to complete the line of melting and metal handling equipmentcovered herein. We hope you find this useful.

For more information or additional copies of this booklet,

please contact us.

Metallurgical Equipment Division

WHITING EQUIPMENT CANADA INC. Welland, Ontario, Canada

+1 905-732-7585

To Our F r iends

in the Metal Casting

Industry:



POINTS TO CONSIDER IN PLANNINGNEW CUPOLA INSTALLATION

Tonnage Requirements

Mechanical charging

Air weight control and recording

Hot blast system

Moisture control

Water cooling for heats of 16 hours and over

Slag Handling and Disposal

Front slag spout for continuous tapping, lower carbons and higher temperatures

Insulated mixing and desulphurizing ladle, forehearth, or duplexing furnace

Cupola service platform at charging door

Height of charging opening

Tappers platform

Cast iron block lining at charging zone

Blower capacity

Facilities for removing bottom drop

Bottom door hoist

Weighing and recording of charge materials

Emission Control Equipment

Roof hood

Ample height of cupola legs to allow for mixing ladle, forehearth or duplexing furnace

Automatic gas vents in wind box

Safety Overflow Spout

Page 2



POINTERS ON CONVENTIONALCUPOLA OPERATION

1. AIR SUPPLY

Make sure that the blower or fan is in good operating condition, particularly the bearings. Check the air line from blower to windbox for possible leaks. Check air losses with the air circuit under pressure. Check

function and calibration of air weight controller.

2. LINING

Check for proper repair after each heat. See that all slag adhering after the heat is removed and worn

spots patched up. Lining should be repaired to a true circle at all times.

3. BOTTOM PLATE AND DOORS

Inspect frequently for distortion or cracks.

4. BLAST PRESSURE

See that the pressure gauge is working correctly and that it registers zero when the pressure is actually

zero.

5. SAFETY SPOUT

Make sure that the lead disc is in place and clear from sand and clay.

6. TAP HOLE AND SLAG HOLE

These should be maintained at the desired size and positions.

7. TUYERES

Tuyeres should fit tight against the shell to minimize air leakage. These joints should be regularlyinspected and kept sealed with suitable refractory.

8. SCALES

Scales for weighing up charges should be checked frequently. We recommend separate scales for metallic charges and for coke and stone.

9. CHARGES

Keep close tab on the charge makeup. See that proper amounts of pig, scrap, coke, and flux are

delivered to the cupola as called for by the metallurgist. Check the tares for buckets and harrows used inmaking up charges.

10. SIZE OF MATERIALS

Pig iron as well as scrap should not be larger than 1/3, and the coke from 1/10 to 1/12 of the inside

diameter of the cupola.

11. TEMPERATURE

Check metal temperatures with pyrometer. Know what you are getting. Have pyrometer checked for accuracy.

12. ANALYSIS

Analyze all materials going into the cupola, also the test bars from every heat. Make chill tests

frequently.

13. LOG

Insist on an accurate record of every heat.

NOTE: Heavy exhaust systems in the foundry may create a partial vacuum condition, causing a down draft

through the cupola stack. The cupola building should be properly vented.

Page 3



APPOXIMATE MELTING RATES IN TONS PER HOUR FORWHITING LINED CUPOLAS (Uninterrupted Operation)

METAL TO COKE RATIO (CRecommendedBlower Cap'y.

6:1 7:1 8:1 9

333#/ton 286#/ton 250#/ton 222

CupolaSize

ShellDiam.

LowerLiningThick-ness**

Diam.InsideLining

AreaInsideLining

Sq.In.

Theoretical Air Flow

thruTuyeresSCFM

VolumeICFM

Pressureoz./in.

2* 99ft

3/#c 107ft

3/#c 112ft

3/#c 118

0 27" 4½" 18" 254 573 640 8 1.1 1.3 1.4 -

1 32" 4½" 23" 415 937 1040 16 1.9 2.0 2.2 2

2 36" 4½" 27" 573 1293 1430 20 2.6 2.8 3.1 3

2½ 41" 7" 27" 573 1293 1430 20 2.6 2.8 3.1 3

3 46" 7" 32" 804 1815 2000 24 3.7 4.0 4.3 4

3½ 51" 7" 37" 1075 2426 2700 24 4.9 5.3 5.8 6

4 56" 7" 42" 1385 3126 3450 24 6.3 6.8 7.4 7

5 63" 9" 45" 1590 3589 4000 28 7.3 7.8 8.5 9

6 66" 9" 48" 1810 4085 4500 32 8.3 8.9 9.7 1

7 72" 9" 54" 2290 5170 5750 32 10.4 11.3 12.3 1

8 78" 9" 60" 2827 6380 7100 32 12.9 13.9 15.2 1

9 84" 9" 66" 3421 7720 8600 36 15.6 16.8 18.4 1

9½ 90" 9" 72" 4072 9190 10200 36 18.6 20.0 21.9 2

10 96" 9" 78" 4778 10790 11900 36 21.8 23.5 25.7 2

11 102" 12" 78" 4778 10790 11900 36 21.8 23.5 25.7 2

12 108" 12" 84" 5542 12510 13900 36 25.3 27.3 29.8 3

* Additional pressure capacity may be required when auxiliary equipment is added to the blast system or when ** For long heats use heavier lining or use water cooling.

Page 4



APPOXIMATE MELTING RATES IN TONS PER HOUR FORWHITING LININGLESS HOT BLAST CUPOLAS (Uninterrupted Ope

METAL TO COKE RATIO (Carbon CRecommended

Blower Cap'y. 5:1 6:1 7:1 8:1

400#Coke/Ton 333#Coke/Ton 286#Coke/Ton 250#Cok

CupolaI.D. ofMeltZone

Cupola AreaSq.In.

Theoretical

Air Flowthru

TuyeresSCFM

VolumeICFM

Pressureoz./in2*

86ft3/#c 99ft

3/#c 107ft

3/#c 112ft

3/

54" 2290 5170 6000 48 10.0 10.4 11.3 12.3

60" 2827 6380 7100 48 12.4 12.9 13.9 15.2

66" 3421 7720 8600 48 15.0 15.6 16.8 18.4

72" 4072 9190 10500 56 17.8 18.6 20.0 21.9

78" 4778 10790 12000 56 20.9 21.8 23.5 25.

84" 5542 12510 13900 56 24.2 25.3 27.3 29.890" 6362 14360 16000 64 27.8 29.0 31.3 34.2

96" 7238 16340 18000 64 31.7 29.0 35.6 38.9

102" 8171 18440 20300 72 35.7 37.3 40.2 43.9

108" 9161 20680 22800 72 40.1 41.8 45.1 49.2

114" 10207 23040 25500 80 44.7 46.5 50.2 54.9

NOTES: For larger Cupola sizes consult Whiting Metallurgical Equipment Division* Recommended minimum pressure for use with 1000º F. Whiting-Thermo hot Blast Heater

For detailed specifications consult Whiting Metallurgical Equipment Division



D

A B

D

Key

A. 9” 4 ½” x 2½”Straight

B. 9” x 4½” x 9” CalliauBlock

C. 9”x 4½” x 2” Straight

7” LINING

.9D Approx.

A B

A B

A B

A B

A B

A B

A B

Key

A. 9” 4½” x 2 ½”Straights and arches

B. 9” x 6” x 4” Cupola

Block

C. 9” x 4½” x 1 ½” Split

9” LINING

.9D Approx.

B

A B

B

B

A B

B

AB

B

AB

BC

A B

B

B

B A

C

A

A B

B

B

A B

B D

D

BB

B

B

B

B

B

B

B

B

B

B

B

B

B

B

B

A

A

A

A

A

A

A

A

A

A

A

A

D

D

Key

A. 9” 4½” x 2 ½”Straights and arches

B. 9” x 6” x 4” CupolaBlock

10 ½” LINING

.9D Approx.

B

B

B

B

B

B

B

B

B

B

B

B

B

B

B B

B

B

B

B

B

B

B

B

B

B

B

B

B

B

B

B

B B

B

B

A

A

A

C

Key

A. 9”x 4½” x 2½”Straight

B. 9” x 6” x 4” CupoBlock

C. 9”x 4½” x 1¼”Split

D

12” LINING

.9D Approx.

D

CUPOLA LINING DATA

Page 6



CUPOLA LININGSNUMBER OF BRICK AND BLOCK REQUIRED FOR WHITING CUP

NOTE: For long runs, heavier lining may be required. Consult your supplier for other

LOWER LINING U

Mat’ls Req’d per Foot of Height MatCupola

No.

ShellInside

Diam.

Inches

Lining

Thick-ness

Inches

CupolaInside

Diam.

Approx.Inches

Cupola

Block

Size No.

Cupola

Block

Pcs.

9” Str.

Brick

Pcs.

Fire

Clay

Lbs.

TotalWeight

Approx.

Lbs.

Lining

Thick-ness

Inches

9” S

Bric

Pcs

0

12

27”

32”36”

4½”

4½”4½”

18”

23”27”

* “A” 16-25

* “B” 21-30* “C” 27-36

12

1618

3

3

15

2224

335

442494

2½”2½”

2630

2½3

3½

41”46”

51”

7”7”

7”

27”32”

27”

* “C” 27-36* “D” 30-39

* “D” 30-39

* “E” 40-49

1820

6

16

3442

43

4044

47

740863

924

2½”2½”

2½”

3439

43

4

5

6

56”

63”

66”

7”

9”

9”

42”

45”

48”

* “E” 40-49

* * 42-54* * 48-60

* * 48-60

25

2733

63

51

55

56

54

72

76

1067

1390

1447

2½”

4½”

4½”

48

5

11

7

8

9

72”

78”

84”

9”

9”

9”

54”

60”

66”

* * 54-66

* * 60-72

* * 66-78

69

78

84

64

68

74

83

91

98

1681

1778

1920

4½”

4½”

4½”

20

32

42

9½

1011

12

90”

96”102”

108”

9”

9”12”

12”

72”

78”78”

84”

* * 72-84

* * 78-90* * 78-90

* * 90-102

* * 84-96* * 96-108

90

9696

108

102114

80

84

105

115122

130

2063

21943182

3370

4½”

4½”4½”

4½”

52

6572

82



CUPOLA LININGS

ALTERNATE ARRANGEMENTS FOR LOWER LINING, Cupola No. 0 ThUsing Standard arch and Straight Brick (2½” brick)

Materials Required Per Fo

Cupola

No.

ShellInside

Diam.

Inches

LiningThickness

Inches

Cupola

InsideDiam.

(Approx.)

Inches

No. 3Arch

Brick

Pcs.

No. 2Arch

Brick

Pcs.

No. 1Arch

Brick

Pcs.

9” Str.

BrickPcs.

0

12

2½

33½

4

27”

32”36”

41”

46”51”

56”

4½”

4½”4½”

7”

7”7”

7”

18”

23”27”

27”

32”37”

42”

6 40

4842

42

3224

15

720

20

3854

71

34

3943

48

USING STANDARD CIRCLE BRICK (9” x 4½” x 2½”) Cupola No. 1 ThrMaterials Required Per Foo

Cupola

No.

ShellInside

Diam.

Inches

Lining

ThicknessInches

Cupola

Inside

Diam.(Approx.)

Inches

24-33Circle

Brick

Pcs.

36-45Circle

Brick

Pcs.

45-57Circle

Brick

Pcs.

9” Str.

BrickPcs.

12

2½

33½4

32”36”

41”

46”51”56”

4½”4½”

7”

7”7”7”

23”27”

27”

32”37”42”

5844

44

20

20

20

536839

1048

34

394348

Note:– 3” series brick in these shapes are available – fewer bricks with fewer joints wou

Page 8



4½”

2½”

Upper Lining9” x 4½” x 2½”Firebrick

Lower Lining9” x 9” x 4½”Cupola Block

4½”

9”

Linings for Std. CupolasNo. 1-2


Lower Lining9” x 9” x 4½”Cupola Block

Linings for Std. CupolasNo. 2½-3-3½-4

9”

4½”

2½”

4½”

4½”

2 ½ ”

7”


Lower Lining

9” x 4” x 6”Cupola Block

Linings for Std. CupolasNo. 5 to 10 Incl.

4½”

2½”

9”4½”

6” 2 ½ ”

8½”


Lower Lining9” x 4” x 6”

Cupola Block

Linings for Std. CupolasNo. 11 & 12

2½”

4½”

9”

6” 6”

STANDARD LINING ARRANGEMENTS

ALTERNATE ARRANGEMENTS FOR UPPER LININGS

FOR CUPOLAS NO. 5 THROUGH NO. 12Using Standard Circle Brick (9” x 4½” x 2½”)

MATERIALS REQUIRED PER FOR OF HEIGHT

Cupola

No.

Shell Inside

Diam. Inches

Upper Lining Thick-

ness Inches

Diam. Inside Upper Lining

(Approx.) Inches

48-57Circle

BrickPcs.

60-69Circle

BrickPcs.

72-81Circle

BrickPcs.

84-93Circle

BrickPcs.

96-105Circle

BrickPcs.

108-117Circle

BrickPcs.

FireClay

Lbs.

TotalWeight

(Approx.)Lbs

56

789

9½10

1112

63”66”

72”78”84”

90”96”

102”108”

4½”4½”

4½”4½”

4½”4½”4½”

4½”4½”

54”57”

63”69”

75”81”

87”93”99”

4820

5892

8229

44106

10134

44120

11124

53149120 63

44

4750

555863

656975

800

852919

100010791160

123813181400

NOTE:–3” series brick in these shapes are available – fewer brick

with fewer joints would be required.

Page 9



RECOMMENDED TAP HOLE SIZESFOR CONTINUOUS TAPPING

AND BACK SLAGGING

Melting Rate inTons per hr.

5 10 15 20 25

Diameter

Tap Hole 1/2” 5/8” 3/4” 1” 1-1/8”

EquivalentPipe Size

1/4” 3/8” 1/2” 3/4” 1”

NOTE: For other than round holes, use equivalent cross-sectional area

GOOD MONOLITHIC REFRACTORY LINING(Acid) for Cupola Melting Zones, Converters,

Ladles, Electric Furnace Bottoms, etc.

50% — Minus 3/8” Silica Ganister

30% — Minus 1/8” Silica Ganister

14% — 140 Mesh or finer—Silica Flour

6% — Western Bentonite

7% — Or More Water by weight (Use as much water as possible without causing puffing

while ramming).

Mull in good muller eight (8) minutes or more.

Ram as hard as possible around steel form.

Dry slowly at 600°F. as long as practicable; up to 36 hours is desirable.

Heat slowly from 600° to 1250°F. in 3 to 4 hours.

Preheat from 1250 to 2000F. before charging with molten iron.

NOTE:— To guide those wishing to make screen test on mixture. Particle size distribution of drymixture should be as follows:

On 28 Mesh 53 to 55%

Thru 28 Mesh on 65 Mesh 14 to 14½ %

Thru 65 Mesh 33 to 36½ %

Page 10



SLAG NOTCH SKIMMER BRIC

S†

H*

DRAIN HOLE

TAP HOLE

SAND BOTTOM

* H inches > cupola pressure oz./in† 1½” to 2”

Melting rate in tons per hour 5 10 15 20

Minimum Diameter of tap hole 1-1/4” 1-3/4” 2-1/4” 2-1/2” 2

Equivalent Std. Pipe Sizes 1” 1-1/2” 2” 2-1/2” 2

NOTE: For other than round holes, use equivalent cross-sectional area

RECOMMENDED TAP HOLE SIZES FOR FRONT SLAGGING

FRONT SLAGGING

ME



Effluent

Gas

Fractionof 1 Lb.

CarbonBurned to

Air Requirements

Lbs. per 1 Lb.

Carbon

Gases Produced

Lbs. per

Lb. Carbon

Heat Develope

BTU. per Lb.

Carbon

CO2% CO% N2%A

CO2

B

COO2 N2 Air CO2 CO N2 Total CO2 CO T

0

12

34.7

33.031.4

65.3

66.066.6

0.000

0.0290.060

1.000

0.9710.940

1.33

1.371.41

4.44

4.574.70

5.77

5.946.11

0.00

0.110.22

2.33

2.262.19

4.44

4.574.70

6.77

6.947.11

000

422873

4350

42244089

4

44

34

5

29.728.1

26.4

67.367.9

68.6

0.0920.125

0.159

0.9080.875

0.841

1.451.50

1.54

4.854.99

5.14

6.306.49

6.68

0.340.46

0.58

2.112.04

1.96

4.854.99

5.14

7.307.49

7.68

13381819

2314

39503806

3658

55

5

6

78

24.7

23.121.5

69.3

69.970.5

0.195

0.2320.271

0.805

0.7680.729

1.59

1.641.69

5.30

5.475.64

6.89

7.117.33

0.71

0.850.99

1.88

1.791.70

5.30

5.475.64

7.89

8.118.33

2837

33763943

3502

33403171

6

67

910

11

19.818.2

16.5

71.271.8

72.5

0.3120.354

0.400

0.6880.646

0.600

1.751.80

1.87

5.826.01

6.21

7.577.81

8.08

1.151.30

1.47

1.601.51

1.40

5.826.01

6.21

8.578.82

9.08

45405151

5820

29932810

2610

77

8

12

1314

14.8

13.211.6

73.2

73.874.4

0.447

0.4960.547

0.553

0.5040.453

1.93

1.992.07

6.42

6.646.86

8.35

8.638.93

1.64

1.822.01

1.29

1.171.06

6.42

6.646.86

9.35

9.639.93

6504

72177959

2406

21921971

8

99

151617

9.98.36.6

75.175.776.4

0.6020.6580.720

0.3980.3420.280

2.132.212.29

7.117.357.63

9.249.579.92

2.212.422.64

0.920.800.65

7.117.357.63

10.2410.5710.92

8759957610476

173114881218

101111

18192021

5.03.31.70.0

77.077.778.379.0

0.7830.8520.9221.000

0.2170.1480.0780.000

2.382.472.572.67

7.918.218.528.87

10.2910.6811.0911.54

2.873.133.393.67

0.510.340.180.00

7.918.218.528.87

11.2911.6812.0912.54

11393123971341014550

944644339000

12131314

* See Page 13 for an explanation and example of the

data contained in this chart.

AIR REQUIREMENTS FOR COMBUSTION*(60° F Temp. and 29.92 Inches of Mercury)

Page 12



EXPLANATION.

(1) C + O2 = CO2 (2) CO2 + C = 2CO

For a gas analysis of 14 percent CO2 the table shows 11.6 percent CO and 74.4 percent N2 and the 11.6 preduction of CO2 no free oxygen being involved. It is now necessary to resort to the use of the Law of He

of a series of reactions is the same regardless of the intermediate steps, and thus, when (2) is added to (1)

2C + O2 = 2COor C + ½ O2 = CO

This reaction does not actually take place, but by the Law of Hess, its occurrence can be assumed.

The CO content of the effluent gases in the problem under consideration has been shown to be 11.6 per c

results from the incomplete combustion of a certain amount of carbon of the coke. At the same time 14 p

the carbon that is completely consumed initially, When 1 lb. C is burned under these conditions, the frac

Cco2 = 14/(14 + 11.6) = 0.547and the fraction burned to CO is Cco = 11.6/(14 + 11.6) 0.453

Consequently, the air required to form CO is 0.547 x 151* = 82.6 cu. ft.

and that required to form CO 0.453 x 75.5** = 34.2 cu. ft.

The total volume of air used to burn one pound of carbon under these conditions is 116.8 cu. ft. It has be

iron is being melted at a ratio of 10 to 1, therefore 200 lbs. of coke containing 90% carbon, or 180 lbs. of

total air consumption is

180 x 116.8 = 21,000 cu. ft. (approximately)

* 151 Cu. ft. of air required to burn 1 lb. of carbon to CO2.

** 755 Cu. ft. of air required to burn 1 lb. of carbon to CO.



RELATIONSHIP BETWEEN METALTEMPERATURE AND MELTING RATE FOR

VARIOUS BLAST RATES AND FUEL RATIOS

2800

2780

2760

2740

2720

2700

2680

2660

2640

2620

2600

2580

2560

2540

2520

2500

2480

2460

2440

2800

2780

2760

2740

2720

2700

2680

2660

2640

2620

2600

2580

2560

2540

2520

2500

2480

2460

244014 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56

Relationship between metal temperature and meltingrate for various blast rates and fuel ratios, from datareported by Massori and Lindsay.

– G.C. Wright – American Foundryman Nov. ‘47

Lbs. Metal per Minute per Sq. Ft. Cupola Area

Lbs. Metal per Hour per Sq. Ft. Cupola Area

10 15 20

Area of CupolaI.D.Cupola Sq. In. Sq. Ft.

24

30

36

42

45

48

54

60

66

7278

84

452.3

706.8

1017.8

1385.4

1590.4

1809.5

2290

2827

3421

40724778

5542

3.142

4.909

7.069

9.621

11.04

12.57

15.90

19.65

23.76

28.2733.18

38.48

MELT RATE

T E M P E R A T U R E ° F

Cu. Ft. per Min. perSq. In. Cupola Area

Lbs. Carbon per Ton(2000 Lbs) Metal

Lbs. Metal perLb. Carbon

Cu. Ft. per Min. per Sq. Ft.Cupola Area

1 . 4

6

1.65

1.94

2.202.43

2.92280

260

240

220

200

180

160

140

120

420350317

280

235

21016.7

14.3

12.5

11.110.0

9.1

Page 14



FORMULA FOR ESTIMATINGHEIGHT OF BED COKE

Multiply the square root of the blast pressure by 10.5 and add a factor F for operational

variables.

Coke Bed Height (above Tuyeres) in inches = F)(ox./in.

Press.BoxWind5.10

2 +×

For normal operating conditions and using a cone bottom charging bucket, an F factor of 6 may be used. For other than normal operating conditions or when they are not exactly known (as

when starting up a new installation), the proper value for F may vary up to 12 to 18 maximum. If

lower carbon iron is desired, the F factor is lower than if high carbon iron is desired. If a quick bottom release charging bucket is used, a higher F value is indicated. Some believe if the coke

size is smaller or larger than one-tenth 1/10) to one-twelfth (1/12) of the inside diameter of the

cupola lining, F is greater. Other conditions may affect the value too.

Example: Given a blast pressure of 16 oz., the square root is 4, and 10.5 x 4 is 42.0.Using F = 6, the bed coke should be 48” above the tuyeres; for F = 12, it would be 54”;

and for F = 18, it would be 60”; all for a 16 oz. blast.

This should serve to estimate starting requirements. The exact value of F may be established

for a particular installation and operation by adjusting the initial value, as suggested above,according to the results obtained and desired.

APPROXIMATE HOLDING CAPACITYOF CUPOLA WELL

Dia. inside lining(inches)

Approx Molten Iron HoldingCapacity Cupola Well(lbs.)

23

273237

4245

485460

6672

7884

570

82011601540

19902280

261033904050

49105840

68407960

(Figures based on (1) 12-inch average depth of metal, and (2) molten metal occupies 46 percent

of available volume of the well.)

(Courtesy AFS—“The Cupola and Its Operation”)

Page 15



AIR

0.020

0.018

0.016

0.014

0.012

0.010

0.008

0.006

0.004

0.002

0.00020 30 40 50 60 70 80 90

70 80 90 100 110 120 130 140 150 160 170 180 190 200 210

0.00

0.05

0.10

0.15

0.20

0.25

0.30

0.35

0.40

0.45

0.50

Percentage relative humidity curves

Percentage relative humidity curves

Temperature °F

H u m i d i t y

, p o u n d s w a t e r v a p o r p e r p o u n d

d r y a i r

Temperature °F

H u m i d i t y , p o

u n d s w a t e r v a p o r p e r p o u n d d r y

a i r

Psychrometric chart: temperature range, 20° to 90°F; pressure, 29.921 in. Hg.

Psychrometric chart: temperature range, 10° to 210°F; pressure, 29.921 in. Hg.

(Both charts by permission of O.T. Zimmerman, author, and publishers of Kent

Engineering Handbook.)

Page 16



20,000

18,000

16,000

14,000

12,000

10,000

8,000

6,000

4,000

2,000

0

400 800 1200 1600 2000 2400 2800 3200 36

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1

Grains%

In12345

6789

1011121314151617181920

*Based on Sta

Grains Water per Cu. Ft. of Blast

Lbs. of Coke per Hour

C u .

F t . B l a s

t p e r

M i n u

t e

COKE CONSUMPTION DUE TO MOISTURE

NOTE: To obtain grains of water per std. Cu. ft. of air, multiply lbs. of water per

dry air by 534.8



STANDARD HYDRO-ARC FURNACE SHELL CAPACITIES

Furnace capacitiesare based upon

lining burned backto this dimension

Slag allowance is basedupon 1 cu. ft. per ton of hotmetal. May be varied withoperational requirement

These dimensionsmay be increasedto add more scrapholdingcapacity

This dimensionmay be increa-sed for hot metalcapacity

Floor line

For duplexing or hot metal operationsthis dim. May be increased by as muchas 25% to increase hot metal capacity

¼E

¼E

C

A

D

E

S

Slim line

H

G

F

J

B

Inside Shell

Dia. A

DepthB

MoltenMetalCapy.To SillLineLbs.

MoltenMetal

Wt. PerInch ofDepthLbs.

ScrapCapy.Cu. Ft.

Capy.Per

Foot ofDepthCu. Ft.

InsideDia.New

LiningC

TotalLiningThick-ness

D

BrickThick-ness

E

MetalDepthTo Sill

F

BottomThick-ness

G

Shell Above

SillJ

SillHeight AboveFloor

K

DepthPanels

L

Aprox.Slag

Allow-ance

S 3'-4" 2'-6" 900 150 7 4.3 2'-4" 6" 6” 7 1/2" 9" 13½” 2'-8" ----- 1”

4'-0" 3'-0" 1800 250 14 7.1 3'-0" 6" 6” 9 1/2" 10" 16½” 2'-8" ----- 1½”

5'-0" 3'-9" 3540 450 31 12.6 4'-0" 6" 9” 11" 12" 1'-10" 2'-6" ----- 1½” 6'-0" 4'-6" 6220 700 51 19.6 5'-0" 6" 9” 1'-1" 15" 2'-2" 2'-6" ----- 2”

7'-3" 5'-6" 10770 930 97 26 5'-9" 9" 9” 1'-4" 17" 2'-9" 2'-6” 1'-3" 2¼”

8'-0" 6'-0" 14100 1190 135 33.2 6'-6" 9" 9” 1'-5" 18" 3'-1" 2'-4" 1'-7" 2½”

9'-0" 6'-9" 20700 1580 210 44.2 7'-6" 9" 13½” 1'-7" 18" 3'-8" 2'-4" 2'-2" 2¾”

10'-0" 7'-6" 33000 2030 310 56.7 8'-6" 9" 13½” 1'-11" 18" 4'-1" 2'-4" 2'-7" 3¾”

11'-0" 8'-3" 44500 2540 435 70.9 9'-6" 9" 13½” 2'-1" 18" 4'-8" 2'-4" 3'-2" 3¾”

12'-6" 9'-9" 65200 3100 640 86.6 10'-6" 12" 13½” 2'-5" 20" 5'-8" 2'-4" 4'-2" 4”

13'-6" 10'-5" 80600 3560 800 99.4 11'-3" 13½” 13½” 2'-7" 20" 6'-2" 2'-4" 4'-8" 4”

14'-0" 11'-0" 94000 3890 925 108 11'-9" 13½” 13½” 2'-9" 21" 6'-6" 2'-4" 5'-0" 4½”

15'-0" 11'-10" 116200 4580 1190 128 12'-9" 13½” 13½” 2'-11" 21" 7'-2" 2'-4" 5'-8" 4½”

16'-0" 11'-11" 136300 5320 1380 149 13'-9" 13½” 13½” 3'-0" 21" 7'-2" 2'-4" 5'-8" 4½”

17'-0" 12'-4" 163100 6120 1600 171 14'-9" 13½” 13½” 3'-2" 24" 7'-2" 2'-4" 5'-8" 4½”

18'-0" 12'-5" 187500 6980 1830 195 15'-9" 13½” 13½” 3'-3" 24" 7'-2" 2'-4" 5'-8" 5” 19'-0" 12'-6" 213700 7900 2080 220 16'-9" 13½” 13½” 3'-4" 24" 7'-2" 2'-4" 5'-8" 5”

20'-0" 13'-4" 241900 8870 2520 247 17'-9" 13½” 13½” 3'-5" 24" 7'-11" 2'-4" 6'-5" 6”

21'-0" 14'-5" 291800 9890 3100 276 18'-9" 13½” 13½” 3'-8" 24" 8'-9" 2'-4" 7'-3" 7”

22'-0" 14'-7" 337100 10980 3470 306 19'-9" 13½” 13½” 3'-10" 24" 8'-9" 2'-4" 7'-3" 7½”

23'-0" 15'-1" 396400 12120 3880 338 20'-9" 13½” 13½” 4'-1" 27" 8'-9" 2'-4" 7'-3" 8”

24'-0" 15'-3" 451600 13310 4300 372 21'-9" 13½” 13½” 4'-3" 27" 8'-9" 2'-4" 7'-3" 8”

25'-0" 15'-4" 497400 14570 4710 407 22'-9" 13½” 13½” 4'-4" 27" 8'-9" 2'-4" 7'-3" 8½”

26'-0" 15'-5" 545500 15880 5150 443 23'-9" 13½” 13½” 4'-5" 27" 8'-9" 2'-4" 7'-3" 9”

28'-0" 15'-10" 645200 18660 6060 521 25'-9" 13½” ----- 4'-7" 30" 8'-9" 2'-4" 7'-3" -----

30'-0" 15'-11" 737000 21670 7010 605 27'-9" 13½” ----- 4'-8" 30" 8'-9" 2'-4" 7'-3" -----

32'-0" 16'-10" 832900 24910 8020 695 29'-9" 13½” ----- 4'-9" 30" 8'-9" 2'-4" 7'-3" ----- Ratings Based on Molten Density of 430 lbs/cu .ft.

L

Page 18



GRAPHITE ELECTRODES(Courtesy Union Carbide Corp.)

(TYPICAL CURRENT CARRYING RANGES – OPEN ARC APPLICATIONS)

The chart below is based on the heating effect in a graphite electrode column from applying anassumed average phase current. Among other important operating factors, however, which must

be considered before selecting the electrode grade and size for your particular application arethese:

• Type of scrap • Proximity of side wallsto electrode circle

• Method of charging • Meltdown time/total heattime ratio, tap-top-tap

• Electrode column length below holder • Type of fume system

TYPICALCURRENT CARRYINGRANGE

8200 12300

16400 20500 24600 28700

120

100

80

60

40

20

inches►

mm ►

0

P h a s e C u r r e n t ( K i l o - A m p e r e s )

Electrode Diameter

ELECTRIC ARC FURNACE TRANSFORMERS(Approximate equivalent capacities)

Multiply: By: To Get:

KVA rating @ 35° C.


KVA rating @ 45° C.KVA rating @ 50° C.


1.44

1.30

1.181.08

0.930.90





Page 19



0 400 800 1200 1600 2000 2400 2

2066°FMelting Point for

43% Carbon Iron

% Carbon by Wt.

4 3 2 1

A

B

C

KEYCurve “A” – TheoreticalCurve “B” – Actual for Large

FurnacesCurve “C” – Actual for Small

Furnaces

Curve “A” taken from pg20 ofMetals Handbook 1936. Thiscurve based on investigationsby Wust, Meuthen andDuerrer.

POWER COMSUMED IN MELTING IRON AND STEEL WITH AN ELECTRIC

650

600

550

500

450

400

350

300

250

200

100

150

50

KHW P E RT ON

TEMPERATURE, °F

HYDRO-ARC FURNACE DATA

Page 20



WHITINGVERTICAL TYPE

LINE FREQUENCY CHANNEL INDUCTION FURNACE

F

ED

1

2

C

C

B

A I.D.

Clearance @

Full Tilt

J

KH

G

4’-2

3

4

5

6 7

8

9

10

1. POUR SPOUT2. HOT METAL INLET3. SLAG BUCKET – NOTE: 15° BACK TILT4. FOUNDATION & TILT STAND5. HYDRAULIC TILT CYLINDER6. SLAG DOOR7. FURNACE ROOF8. FURNACE SHELL9. INDUCTOR COOLING FRAME10. INDUCTOR UNITNOTE: a) POUR SPOUT AND HOT METAL

INLET MAY ALSO BE SUPPLIEDOPPOSITE HAND.

b) ALSO AVAILABLE WITH ROOFLIFT & SWING MECHANISM FORCOLD CHARGING.

c) ALSO AVAILABLE FOR TWOINDUCTOR ACCOMMODATION.

IRONCAPACITY

(TONS)

V C F

T Y P E A B C D E F G H J I.D. K

U S A B L E

H E E L

T O T A L

8 10’-10’ 5’-5” 2’-11” 3’-11” 3’-10” 5’-6” 2’-2” 5’-3” 14’-2” 7’-1” 12” 8 3 11

15 12’-6” 6’-3” 3’-6” 4’-8” 4’-8” 6’-5” 2’-2” 6’-3” 16’-6” 8’-3” 12” 15 5 20

20 13’-2” 6’-7” 3’-8” 4’-10” 4’-8” 6’-8” 2’-4” 6’-9” 17’-3” 8’-8” 12” 20 6 2630 14’-10” 7’-5” 4’-0” 5’-3” 4’-8” 7’-6” 2’-7” 6’-9” 18’-10” 9’-9” 12” 30 7 37

40 14’-10” 7’-5” 4’-0” 5’-3” 4’-8” 7’-6” 2’-7” 8’-5” 18’-10” 9’-9” 12” 40 10 50

50 17’-6” 8’-9” 4’-9” 6’-3” 4’-7” 8’-2” 2’-8” 8’-3” 20’-6” 11’-0” 22” 50 12 62

NOTE: Dimensions are approximate and may vary with operational requirement.

Page 21



WHITINGHORIZONTAL TYPE

LINE FREQUENCY CHANNEL INDUCTION FURNACE

152

7

8

93

6

5 4

BC A

E

D

F

J

KKR3

R4R1

R2

B

C A1. POUR SPOUT2. HOT METAL INLET

3. TILT ROLLER ASSEMBLY4. TILT DRIVE5. TILT CHAIN6. SLAG DOOR (OPEN POSITION)7. FURNACE SHELL8. INDUCTOR COOLING FRAME9. INDUCTOR UNITNOTE: a) POUR SPOUT AND HOT METAL

INLET MAY ALSO BE SUPPLIEDOPPOSITE HAND.

b) POUR SPOUT CAN BE OF ENDPOUT TYPE AS SHOWN OR OFFRONT POUR TYPE.

IRONCAPACIT

(TONS)

H C F

T Y P E

F I G A B C D E F G H J K R1 R2 R3 R4

U S A B L E

H E E L

35 1 13’-6” 20’-6” 4’-0” 7’-10” 2’-2” 8’-7” 1’-6” 2’-6” 4’-0” 35° 4’-7” 5’-7” 8’-10” 5’-2” 35 10

50 1 15’-10” 22’-10” 4’-0” 8’-0” 2’-5” 8’-9” 1’-6” 2’-6” 4’-0” 35° 4’-9” 5’-9” 9’-0” 5’-4” 50 14

65 1 18’-4” 25’-4” 4’-0” 8’-0” 2’-5” 8’-9” 1’-6” 2’-6” 4’-0” 35° 4’-9” 5’-9” 9’-0” 5’-4” 65 15

85 1 17’-6” 24’-6” 4’-0” 9’-0” 3’-0” 9’-3” 2’-0” 3’-0” 5’-0” 35° 5’-3” 6’-3” 9’-6” 6’-3” 85 15 1

110 1 22’-2” 29’-2” 4’-0” 10’-0” 3’-0” 9’-3” 2’-0” 3’-0” 5’-0” 35° 5’-3” 6’-3” 9’-6” 6’-3” 110 20 1

150 2 26’-9” 33’-9” 4’-0” 10’-0” 3’-0” 9’-3” 2’-6” 5’-0” 6’-0” 35° 5’-3” 6’-3” 9’-6” 6’-3” 150 27 1

200 2 28’-6” 35’-6” 4’-0” 10’-6” 3’-3” 9’-9” 2’-6” 5’-0” 6’-0” 35° 5’-9” 6’-9” 10’-0” 6’-7” 200 35 2

NOTE: Dimensions are approximate and may vary with operational requirement.

FIG.-1

FIG.-2

Page 22



USEFUL DATA ON COMBUSTION

AIR

Consists of 23% (by weight) of oxygen and 77% (by weight) of nitrogen; or by volume 20.7%

oxygen and 79.3% nitrogen. One pound at 62° F. (barometer at 30 inches) occupies 13.1 cu. ft., and 56cu. ft. at this temperature contain 1 lb. of oxygen.

OXYGEN—O

One pound at 62° F. occupies 12 cu. ft. According to Welters theory, any material burned with one

pound of oxygen evolves 7,560 B.T.U.

CARBON—C

One pound requires for its complete combustion 2-2/3 lbs. of oxygen, or, 11.54 lbs. air—151 cu. ft.

of air, developing 20,160 B,T.U., of which 5,760 are latent, being expended in vaporizing the carbon;

leaving 14,400 sensible. If perfect combustion takes place, 12,610 effective B.T.U. may he realized

with the escaping flue gases at 600° F:

CARBON MONOXIDE—CO

One pound occupies 13½ cu. ft. at 62° F. requires 4-7 lb. of oxygen or 32 cu. ft. of air for itscombustion and evolves 4,320 B.T.U. With perfect combustion and escaping flue gases at 600° F.,

3,820 effective B.T.U. may be realized. One cu. ft. requires 2.4 cu. ft. of air for combustion andevolves 320 B.T.U.

HYDROGEN—H

One pound at 62° F. occupies 190 Cu. ft., requires 8 lbs. of oxygen or 450 Cu. ft. of air for itscombustion and evolves 60,480 B.T.U. when burned to liquid water. 42,000 B.T.U. may be realized

with flue gas at 600° F. One cu. ft. of hydrogen gas requires 2-1/3 cu. ft. of air for its combustion and

evolves 324 B.T.U.

SULPHUR—S

One pound requires one pound of oxygen or 56 cu. ft. of air for combustion and evolves 4,000BT.U., exclusive of the heat required for volatilization of the sulphur. With perfect combustion and

flue gases at 600° F., 3,260 B.T.U. may be realized.

NATURAL GASOne pound occupies 22 cu. ft. at 62° F., or 1,000 cu. ft. weigh 45 lbs. One cu. ft. requires 10 cu. ft.

of air for its combustion and evolves about 1,000 B.T.U.

OIL (BEAUMONT)

Specific gravity .92 weighs 7-2/3 lbs. per gallon. One barrel of 42 gals. weighs 322 lbs. Requires for

complete combustion 15 lbs. of air per lb. of oil or 1,500 cu ft. of air per gallon of oil. One poundgives about 20,000 B.T.U.

HEAT

Evolved by the combustion of any organic fuel, such as coal, is approximately that of its carbon plus

that of as much of its hydrogen as exceeds the amount required to combine with its oxygen to form

water. Pulverized coal weighs approximately 35 lbs. per cu. ft.

EXAMPLEIf a fuel consists of 87% C, 5% H and 8% O, the 8% of oxygen will be sufficient to combine with

1% of hydrogen, leaving 4% of that element available for combustion. The B.T.U. to be derived from

1 lb. of this fuel will then be that corresponding to .87 lbs. of carbon plus .04 lbs. of hydrogen.

The above statements are approximately correct for the theoretical amount of air required at 62° F.with the barometer at 30 in. In practice, 10% to 20% more air should be provided because of the

imperfect mixture with the fuel. Further corrections should be made for temperature in hot climates,

also for pressure in high altitudes.

Page 23



SELECTION OF U-TYPE HOLDING LADLE FORDESULPHURIZING WITH SODA ASH

The treatment of molten iron with soda-ash in a ladle or a forehearth has proved a very

practical and economical means of refining and mixing cupola metal, and has been

adopted by many foundries. For this purpose the U-shaped ladle has been found, bycomparative tests, to do the job better and with a smaller amount of refining agent than

any of the other types of reservoirs.

At the same time that the metal is being purified, there is a distinct mixing action whichtends to level off variations in composition.

The U-ladle extends the advantages of a mixer ladle and desulphurizer to foundries

making the lightest grades of castings and with melting rates as low as 2 or 3 tons perhour. The capacity of the mixer ladle may vary widely for the same diameter cupola,

depending upon the class of work, the capacity of the transfer ladle and the extent of

desulphurizing that is desired. For refining light castings, where the iron is taken away in50 or 100 lb. ladles the mixer should have a working capacity of 1/10 to 1/6 the hourly

melting rate. For instance, 600 to 1000 lbs. capacity for a melting rate of 3 tons per hour,or 2400 lbs. to 4000 lbs. for a melting rate of 12 tons per hour where the metal is taken

away in 250 to 1000 lb. transfer ladles; in either case, holding the iron in the ladle incontact with the desulphurizing slag from 6 to 10 minutes. For heavy castings the

capacity may well vary from 1/5 to 1/3 the hourly melting rate, thus providing an elapsed

time of 12 to 20 minutes in the refining ladle.

Extent of DesulphurizingOrdinarily one pound of soda ash per ton of iron is required to neutralize silicates and

cupola slag entrained in the iron. Thereafter further additions reduce sulphur contentabout as shown below:

Metal at Spout Sulphur

.08% .10% .13% .17%

With 2 lb. soda-ash per ton _ _ _ _ _ _ _ _ _ _ _ _ _ _ .070 .085 .110 .145

With 4 lb. soda-ash per ton _ _ _ _ _ _ _ _ _ _ _ _ _ _ .060 .070 .090 .115With 6 lb. soda-ash per ton _ _ _ _ _ _ _ _ _ _ _ _ _ _ .050 .060 .075 .095

The above values are usual for acid cupola operation. Lower sulphurs can be obtainedfrom cupolas operating with basic slag.

Choice of insulation between the refractory lining and the shell ranges from a sheet or

two of ordinary building asbestos paper to 1¼” thick insulating brick.

Page 24



WHITING U-LADLES – IRON CAPACITY IN POUNDS(Figures in bold and underlined indicate lining customarily used)

LiningThick-ness

13½x 46

14½x 50

16x 54

18x 64

19¼x 67½

20x 74

20x 80

20x 90

22½x 90

25x 96

27x 90

34½x 101

34½x 110

4”5”6”

23141856

1460

356029392392

46923934 6258 7742 9302 10202 11702

7”8”9”

1123840

1913

15001146

3258

26592133

53324496

3746

66305714

4841

82486982

5975

89987702

6611

102468906

7678

147031302811477

197001767715791

250392266720442

3936036218

4352840145

10”

11”12”

1675 3079

2488

4056

33552732

5062

42384198

5620

47243918

6557

55384618

10044

87277519

14035

1240510897

18358

1641214599

33243

30431

27724

36937

33895

31024

15”18”

4510 7062 9913 2072314931

2334916999

Capacities based on 411 lbs. per cu. ft. or .238 lbs. per cu. in.

Larger sizes engineered to order.

H J

F

E

G

GAUGE WHEELBASE

A B C D

9½ MIN.

STANDARD SPOUT ARRANGEMENTS

Size E F G H J Ga.

Wheel-

base13½” x 46”14½” x 50”16” x 54”

27”27”35¾”

51”54”65”

18”20”27¾”

58”62”681/8”

13½”13½”183/8”

24”24”36”

79”83”891/8”

18” x 64”19¼” x 67½”

20” x 80”

35¾”35¾”

35¾”

67”69”

69”

26¾”26¾”

24¾”

781/8”815/8”

955/8”

183/8”183/8”

183/8”

36”36”

36”

991/8”1025/8”

1151/8”

22½” x 90”25” x 96”27” x 90”

35¾”35¾”42”

72”74”86”

21¾”15”14”

1055/8”111

5/8”

1055/8”

183/8”18

3/8”

183/8”

36”36”36”

1265/8”132

5/8”

1055/8”

34½” x 101”

34½” x 110”

511/8”

51

1

/8”

90½”

90½”

13½”

13½”

1185/8”

127

5

/8”

20½”

20½”

36”

36”

118½”

127½” Page 25



IRON CAPACITYTaper Side Ladles

Bowl SizeCAPACITIES IN POUNDS (Bold Face and Highlighted figures sho

Lining Thickness

Top Dia.& Depth Bottom Dia.

Top

Allowance1½ 2 2¾ 3½ 4 4¾ 5¼

20½ 18 2 839 717 556 420

21½ 19 2 1001 863 681 525

23 20 2 1247 1087 873 687

24 21 2 1457 1279 1039 830

26 22¾ 2 1921 1707 1415 1156 1002

27½ 24 2½ 2273 2033 1705 1412 1236

29 25½ 2½ 2748 2475 2100 1763 1558

32 28 2½ 3815 3474 3001 2571 2307 1944

34½ 30¼ 3 4838 4439 3881 3370 3054 2616

36 31½ 3 5128 4512 3945 3594 3105 2804

36½ 32 3 5388 4751 4164 3799 3292 2978

40 35 3 7342 6555 5825 3799 3292 2978

40½ 35½ 3 7671 6861 6107 5635 4972 4558

43½ 38 3 8768 7878 7317 6525 6029

44 38½ 3 9138 8222 7646 6830 6318

46 40½ 4 10455 9456 8826 7931 7368

48 42½ 4 12030 10931 10236 9246 8621

48½ 42½ 4 12486 11359 10646 9629 8987

51 44½ 4 13502 12700 11554 10828

52 45½ 4 14499 13657 12454 11691

55 48 5 17212 16270 14920 14061

56 49 5 18381 17397 15985 15085

58 51 5 20876 19804 18263 17280

61 53½ 5 23576 21842 20733

62 54 5 24767 22974 21825

66 58 5 31069 28980 27639 72 63½ 6 38847 37219

77* 70 6 48372 46513

86* 77 7 58383 56301

*NOTE: 79" and 86" ladles are 72" deep. All others have the same depth as top diameter.

Based on density of molten iron at 411 lbs. per cu. ft. or 0.238 lbs. per cu. in.

Page 26



STEEL CAPACITYTaper Side Ladles

Bowl SizeCAPACITIES IN POUNDS (Bold Face and Highlighted figures sh

Lining Thickness

Top Dia.& Depth Bottom Dia.

Top

Allowance1½ 2 2¾ 3½ 4 4¾ 5¼

20½ 18 4 777 662 510 383 310 219

21½ 19 4 935 803 630 482 398 289

23 20 4 1176 1022 816 689 536 403

24 21 4 1381 1209 978 778 660 506

26 22¾ 4 1630 1346 1096 948 749

27½ 24 4½ 1950 1630 1346 1175 946 810

29 25½ 4½ 2388 2020 1690 1491 1221 1060

32 28 4½ 2917 2492 2233 1877 1661

34½ 30¼ 5 3793 3287 2974 2542 2278

36 31½ 5 4426 3863 3515 3031 2733

36½ 32 5 4666 4082 3720 3217 2907

40 35 5 5753 5297 4656 4258

40½ 35½ 5 6038 5566 4904 4491

43½ 38 5 7827 7265 6471 5974

44 38½ 5 8176 7597 6779 6266

46 40½ 6 9417 8783 7883 7318

48 42½ 6 10214 9217 8588

48½ 42½ 6 10630 9606 8959

51 44½ 6 12720 11562 10829

52 45½ 6 13694 12477 11706

55 48 6 16719 15326 14440

56 49 6 17885 16428 15499

58 51 6 20378 18787 17771

61 53½ 7 22048 20920

62 54 7 23208 22040

66 58 7 29359 2799172 63½ 8 39474 37808

77* 70 8 47249

86* 77 9 57161

*NOTE: 79" and 86" ladles are 72" deep. All others have the same depth as top diameter.

Based on 430 lbs. per cu. ft. or 0.25 lbs. per cu. in.



Time temperature curveshowing temperature ofiron from the time it istapped to the last ironfrom pouring ladle,including period ofsuperheating in theelectric furnace.

Courtesy of

Carl F. JosephCentral Foundry

Division (G.M. Co.)

2900

2800

2700

2600

2500

5 25 27.5 30 35

T I M E

S C A L C H A

N G E S

FLUIDITY DANGER

(COVERED)

(OPEN TOP)

E L E C T R I C

F U R N A C E

T A P P E D

F O R H E A R T H

T A P P E D

&

I R O

N

I N T O

F U R N A C E S

T E M P E R A T U R E

I N

D E G

R E E S F A H R E N H E I T

TIME IN MINUTES

Page 28



PRACTICAL METHOD FOR CALCULATINGLADLE CAPACITIES

A

D GG

H

G

F C

E GG

B

V

A – Top Dia. Bowl

B – Bottom Dia. Bowl

C – Height Bowl

D – Top Dia. Inside of Lining

E – Bot. Dia. Inside of Lining

F – Height of Metal

G – Thickness of Lining

H – Top Allowance

V – Vol. of Metal

W – Weight of Metal

Z – Density of Metal

V = Vol. of Metal = F E D

××

+7854.

2

2

W = Z V ×

APPROX. DENSITIES OF VARIOUS METALSIN THE MOLTEN STATE

Metal Lbs./Cu. In. Lbs./Cu. Ft.

Aluminum .079 137

Brass .243 420

Copper .288 487

Cast Iron .238 411

Blast Furnace Iron .231 400

Lead .379 655

Magnesium .056 97

Silicon .0758 131

Steel .250 430

Tin .230 400

Zinc .237 410

Page 29



SUGGESTED CRANE OPERATING SPEEDS – FEET PER MINU

HOIST TROLLEY Capacity

in

Tons Slow Medium Fast Slow Medium Fast Slow

5

7½

10

20

20

20

35

35

30

70

70

60

125

125

125

150

150

150

200

200

200

200

200

200

15

20

25

15

15

15

30

25

25

50

40

30

125

125

100

150

150

150

200

200

175

200

200

200

30

35

40

15

10

8

25

15

15

30

25

25

100

100

100

125

125

125

175

150

150

150

150

150

50

60

75

5

5

5

10

10

10

20

20

18

75

75

0

125

100

100

150

150

125

100

100

75

100

125

150

5

5

5

8

8

8

12

12

12

50

40

30

100

75

50

125

100

100

50

50

50

175200

33

44

55

3030

5050

7575

5050

NOTE: For Floor Controlled Cranes, it is recommended that trolley and bridge speeds not exceed those given

Page 30



HOISTING ROPE

The following table shows breaking strengths for wire rope commonly used on

cranes, ship hoists & winches.

To obtain the safe working load for each diameter of rope, divide the breaking

strength by the factor of safety. Minimum factor of safety for general use is 5:1. Forhot metal handling equipment and high capacity ship hoists 10:1 is recommended.

Wire rope in daily use should be inspected at least once each week and more

frequently if rope is subjected to heavy duty service. Special attention should be givento sections of rope which pass over sheaves as well as all rope end connections.

A special wire rope lubricant should be applied regularly. When installing newhoist rope, not less than 2 turns should remain on the drum when the load is in its

lowest position to relieve stresses on the rope anchor.

Ultimate Strength In Tons Of Improved Plow Steel Wire Rope

Class 6 x 37

6 Strands, 37 Wires/Strand

Class 6 x l9

6 Strands, 19 Wires/Strand Rope

Diam. Fiber Core

Wire Rope

Core Fiber Core

Wire Rope

Core

3/8”

1/16”

1/2”9/16”

5/8”

3/4”

7/8”

1”

1-1/8”

1-1/4”

5.77

7.82

10.212.9

15.8

22.6

30.6

39.8

50.1

61.5

6.20

8.41

11.013.9

17.0

24.3

32.9

42.8

53.9

66.1

6.10

8.27

10.713.5

16.7

23.8

32.2

41.8

52.6

64.6

6.56

8.89

11.514.5

17.9

25.6

34.6

44.9

56.5

69.4

Page 31



SCRAP HANDLING MAGNETS (DEEP COIL)

Diameter, Inches 45” 54” 63” 6

Net Weight, Pounds 2650 4000 6100 77

Head Room Required, Inches 43” 44” 55” 5

Cold Current @ 230 Volts 40 amps. 59 amps. 78 amps. 95 a

Generator Capacity Required 7.5 K.W. 10 K.W. 14 K.W. 17 K

Rectifier Capacity Required 10 K.W. 13.5 K.W. 18 K.W. 22 K

Size of Duplex Flexible Cable #8 B&S #6 B&S #6 B&S #4 B

Recommended Crane Capacity 4 Ton 5 Ton 8 Ton 10

AVERAGE (All Day) LIFTING CAPACITY IN POUNDS

Machine Cast Pig 1500 2560 3970 4

No. 1 Heavy Melting Scrap 1500 2560 3970 4

No. 2 Melting Scrap 1030 1660 2580 3

No. 1 Machinery Scrap (Cast Iron) 815 1300 2040 2

No. 2 Busheling 565 870 1360 1

Steel Turnings 475 725 1230 1

Plate Punchings 1720 3000 4350 5

Page 32



GRADES OF MALLEABLE IRON

GradeUltimate

Lbs./Sq. In.

Yield

Lbs./Sq. In.Elongation %

*

***

Cupola32510 (B)

35018 (A)Pearlitic

40,000 (Min.)50,000 (Min.)

53,000 (Min.)60,000 to 90,000

30,000 (Min.)32,500 (Min.)

35,000 (Min.)43,000 to 70,000

5 (Min.)10 (Min.)

18 (Min.)10 to 2

* Grades 32510 and 35018 refer to A.S.T.M. Specification A-47 and are frequently referred to as grades B and A.

** Specifications on mechanical properties for the many special grades of malleable iron are frequently decided

upon by agreement between producer and consumer.

COLOR SCALE FOR TEMPERATURESThe following color scale permits a rough approximation of high temperatures.

Degrees Degrees

Color Centigrade Fahrenheit

Lowest visible red 475 885

Lowest visible red to dark red 475 to 650 885 to 1200

Dark red to cherry red 650 to 750 1200 to 1380

Cherry red to bright cherry red 750 to 815 1380 to 1500

Bright cherry red to orange 815 to 900 1500 to 1650Orange to yellow 900 to 1090 1650 to 2000

Yellow to light yellow 1090 to 1315 2000 to 2400

Light yellow to white 1315 to 1540 2400 to 2800

White to dazzling white 1540 or higher 2800 or higher

FUSION POINTS OF ASH AND SLAGSCoal Ash

Easily fusible below 1200 below 2200

Moderately fusible 1200 to 1430 2200 to 2600

Refractory above 1430 above 2600

Slags

Acid open-hearth slag approx.1250 approx. 2280

Basic open-hearth slag approx. 1250 approx. 2280

Blast furnace slag approx. 1170 approx. 2140Heating furnace slag approx. 1165 approx. 2130

Courtesy Harbison-Walker Refractories Co.

MELTING POINTS OF MINERALS AND OXIDES°Cent. °Fahr.

Corundum (A12O3) 2050 3722Chromium Oxide (Cr 2O3) 1990 3614Cristobalite (SiO2) 1728 3142.4Forsterite (2MgO●SiO2) 1910 3470Lime (CaO) 2570 4658

Periclase (MgO) 2800 5072Rutile (TiO2) 1825 3317Spinel (MgO●A12O3) 2135 3875Zirconia (ZrO2) 2720 4928Zircon (ZrO2●SiO2) 2550 4622

Mullite (3Al2O3●2SiO2)Mullite melts incongruently at 1830°C. (3326°F.) to form corundum and a silicious liquid. It is

completely melted at approximately 1925°C. (3497°F.).Kaolinite (A12O3●2SiO2●2H2O)

Kaolinite has a P.C.E. value of cone 35, corresponding to a temperature of 1785°C. (3245°F.).

Page 33



INTERNATIONALATOMIC WEIGHTS

Name Symbol AtomicWeight

Name Symbol AtomicWeight

AluminumAntimony

Argon

Arsenic

Barium

Beryllium

Bismuth

Boron

Cadmium

CalciumCarbon

Cerium

Cesium

Chlorine

Chromium

Cobalt

Copper

Fluorine

GalliumGermanium

Gold

Hydrogen

Iridium

Iron

Lead

Lithium

Magnesium

ManganeseMercury

AlSb

A

As

Ba

Be

Bi

B

Cd

CaC

Ce

Cs

Cl

Cr

Co

Cu

F

GaGe

Au

H

Ir

Fe

Pb

Li

Mg

MnHg

26.98121.75

39.95

74.92

137.34

9.01

208.98

10.81

112.40

40.0812.010

140.12

132.91

35.45

52.00

58.93

63.54

19.00

69.7272.59

196.97

1.0080

192.2

55.85

207.19

6.940

24.31

54.94200.59

Molybdenum Nickel

Niobium

Nitrogen

Osmium

Oxygen

Palladium

Phosphorus

Platinum

PotassiumRadium

Selenium

Silicon

Silver

Sodium

Strontium

Sulfur

Tantalum

TelluriumThallium

Thorium

Tin

Titanium

Tungsten

Uranium

Vanadium

Yttrium

ZincZirconium

Mo Ni

Nb

N

Os

O

Pd

P

Pt

KRa

Se

Si

Ag

Na

Sr

S

Ta

TeTi

Tb

Sn

Ti

W

U

V

Yt

ZnZr

95.9458.71

92.91

14. 008

190.2

16.000

106.4

30.97

195.09

39.10226

78.96

28.09

107.87

22.99

87.62

32.06

180.95

127.60204.37

232.04

118.69

47.90

183.85

238.03

50.94

88.90

65.3791.22

Page 34



PROPERTIES OF VARIOUS METALS AND ALLOYS

Density

Specific

Heat

(RoomTemp)

Melting Point

Linear

LengthMetal Symbol

g/cm3 lbs./in.

3 Cal./g/°C °C °F per °

AluminumBrass YellowBronzeBronze CastCadmium

ChromiumCobaltCopperGold

Iron (Cast)Iron (Wrought)LeadMagnesiumManganese

Monel NickelSiliconSilverSteel:

CarbonStainl. 304Stainl. 410

TinTitanium

UraniumZinc

Al

–

–

–

Cd

Cr

Co

Cu

Au

–

Fe

Pb

Mg

Mn

–

Ni

Si

Ag

Sn

Ti

U

Zn

2.708.20-8.608.80-8.78

8.788.648

6.938.718.8919.32

7.03-7.737.8711.361.747.43

8.848.902.33

10.49

7.87.97.7

7.304.51

19.077.13

0.0980.296-0.3100.318-0.317

0.3170.312

0.2500.3150.3210.698

0.254-0.2790.2840.4100.0630.268

0.3190.3220.084

0.379

0.2820.2850.278

0.2640.163

0.6890.258

0.2150.090.090.090.055

0.110.0990.0920.031

0.110.110.031

0.2450.121

0.1270.1050.162

0.056

0.1170.120.11

0.0540.124

0.0280.091

660931

10461050321

1878149710841064

1088-12601510327

6501260

132714551412

962

1482> 1399> 1482

2321670

1132419

1220170819151922610

34122727

19831947

1990-23002750621

12022300

242126512574

1764

2700> 2550> 2700

4503038

2070786

23.6x120.318.418.429.8

6.213.816.814.2

10.611.429.327.123.3

14.013.3 –

19.7

11.017.311.0

238.4

–39.7



THERMAL PROPERTIES OF METALS

SUBSTANCE

Mean

Specific

Heat

60° to

MeltingPoint

BTU per

Lb. Per

°F

Melting

Point

°F

Heat inSolid at

Melting

Point

BTU/Lb.

LatentHeat

of

Fusion

BTU/Lb.

Total

Heat

in Liquidat

Melting

Temp.

BTU/Lb.

Average

Pouring

Temp.

°F

Total

Heat

in Liquid

atPouring

Temp.

°F

BTU/Lb.

Aluminum .254 1220 288 170 458 1380 500

Antimony .054 1167 58.5 68.9 127 1320 136

Beryllium .634 2343 1411 470 1881 2500 1981

Bismuth .032 520 14.0 22.5 36.5 620 40.1

Brass, Muntz Metal (60 Cu, 40 Zn) .120 1660 192 69.0 261 1850 284

Brass, Red (85 Cu, 15 Zn) .105 1880 191 86.5 278 2250 317

Brass, Yellow (65 Cu, 35 Zn) .106 1708 175 84.4 259 2150 306

Bronze, Aluminum (90 Cu, 10 Al) .126 1905 232 98.6 331 2200 368

Bronze, Bearing (80 Cu, 10 Sn, 10 Pb) .095 1832 168 79.9 248 2050 269

Bronze, Bell-Metal .100 1598 154 76.3 230 1900 260

Bronze, Gun-Metal .107 1832 190 84.2 274 2100 303

Bronze, Tobin .107 1625 167 73.5 241 1850 265

Cadmium .060 610 31.3 23.8 55.1 750 65.1

Chromium .156 3412 525 136 661

Copper .105 1983 197 91.1 288 2200 321

Gold .034 1947 62.9 29.0 91.9 2150 100.3

Iron, Pure 60° to 2802°F .168 2802 451 117 568 3100 626

Iron, Pure 60° to 2554°F .168 409* 3.06 412**

Iron, Pure 60° to 1670°F .164 254* 6.53 261**

Iron, Pure 60° to 1414°F .141 184* 0.0 184**

Iron, Cast, Gray (94 Fe, 3.5 C, 2.5 Si) .190 2246 415 41.1 456 2800 583

Iron, Cast, White (97 Fe, 3 C) .180 2102 368 60.3 428 2900 612

Iron, Pig (4.22 C, 1.48 Si, 0.73 Mn,0.12 P, 0.03 S)

.153 2012 299 84.6 384 2300 450

Lead .032 621 17.4 11.3 28.7 720 31.9

Magnesium .281 1202 312 160 472 1380 522

Manganese .182 2300 391 115 506 2400 529

Molybdenum .078 4760 372 126 498

Monel Metal .127 2421 305 122 427 2750 464

Nickel .136 2651 346 133 479 2850 506

Platinum .037 3224 116 49 165

Rhodium .076 3571 262

Silver .062 1764 103 45 148 1950 160

Steel (0.00-0.60 C) .165 2800 445 118 563 3100 621

Steel (0.60-0.80 C) .165 2670 425 118 543 2950 644

Steel (0.80-1.00 C) .165 2600 421 118 539 2900 608

Tin .059 450 21.5 26.1 47.6 650 59.5

Titanium (99.9 Ti) .173 3038 295 100 395

Tungsten .036 6170 220 79 299Vanadium .153 3150 473

Zinc .101 786 70.9 43.4 114 900 125

Zirconium .066 3200 207

* Heat in solid up to transformation point

** Heat in solid after allotropic point

Page 36



Specific Gravity – Density

Gas or VaporChemical

Formula

Specific

Gravity

Air = 1

D

Lb

1 A

Acetylene C2H2 0.9073

Air – 1.0000

Ammonia NH3 0.5963

Butane C4H10 2.0854

Carbon Dioxide CO2 1.5290

Carbon Monoxide CO 0.9671 Ethane C2H6 1.0493

Ethylene C2H4 0.9749

Helium He 0.1380

Hydrogen H2 0.0695

Methane CH4 0.5544

Nitrogen N2 0.9672

Oxygen O2 1.10527

Ozone O3 1.6580

Propane C3H8 1.5620

Sulfur Dioxide SO2 2.2638

PHYSICAL PROPERTIESOF GASES AND VAPORS



PROPERTIES OF DRY AIR

Temp.

Deg. F.

Density,

lb./cu. ft.

Wolume of

1 lb. Dry

Air, cu. ft.

Fraction of

Volume*

Enthalpy

BTU/lb.

0

510

1520

25

303540

455055

60

6570

758085

90

95100

110

120130

140150

160

170

180190

200220240

260

280300

350400

450

500550600

700800900

1000

1200

150018002100

.0863

.0854

.0845

.0836

.0827

.0819

.0810

.0802

.0794

.0786

.0778

.0771

.0764

.0756

.0749

.0742

.0735

.0728

.0722

.0715

.0709

.0696

.0684

.0673

.0662

.0651

.0640

.0630

.0620

.0614

.0601

.0584

.0567

.0551

.0536

.0522

.0490

.0461

.0436

.0413

.0393

.0374

.0342

.0315

.0292

.0272

.0239

.0202

.0175

.0155

11.59

11.7111.83

11.9612.09

12.21

12.3512.4712.59

12.7212.8512.97

13.09

13.2313.35

13.4813.61

13.74

13.8513.9914.10

14.37

14.6214.86

15.1115.36

15.63

15.87

16.1316.29

16.6417.1217.64

18.1518.66

19.16

20.4121.69

22.94

24.2125.4526.74

29.2431.7534.25

36.76

41.84

49.5057.1464.52

. 868

.877

.886

.896

.905

.915

.924

.934

.943

.953

.962

.971

.981

.9901.000

1.0091.0191.028

1.038

1.0471.057

1.075

1.0941.113

1.1321.151

1.170

1.189

1.2081.227

1.2451.2831.321

1.359

1.3961.434

1.5281.623

1.717

1.8111.9062.001

2.1902.3782.567

2.756

3.133

3.7104.2784.834

109.90

111.10112.30

113.50114.69

115.89

117.08118.28119.48

120.68121.87123.07

124.27

125.47126.66

127.86129.06130.26

131.46

132.66133.86

136.26

138.66141.06

143.47145.88

148.28

150.68

153.09155.50

157.92162.73167.56

172.39

177.23182.08

194.25206.46

218.72

231.06243.48255.96

281.14306.65332.48

358.63

411.82

493.64577.51662.99

* Fraction of volume at 70°F or relative volume compared to 70°F (must multiply by 100 for % volume.)

Page 38



TEMPERATURE CONVERSION TABLE NOTE: The Fahrenheit equivalent is shown in the bold type to the right of the Centigrade temperature C.

The Centigrade equivalent is shown in the bold type to the left of the Fahrenheit temperature F.C. F. C. F. C. F. C. F.

-17.8

-17.2

-16.7-16.1

-15.6-15.0

-14.4

-13.9

0

1

2

3

45

6

7

32.0

33.8

35.637.4

39.241.0

42.8

44.6

4.44

5.00

5.566.11

6.677.22

7.78

8.33

40

41

42

43

4445

46

47

104.0

105.8107.6

109.4

111.2113.0

114.8

116.6

26.7

27.227.8

28.3

28.929.4

30.0

30.6

80

81

82

83

8485

86

87

176.0

177.8179.6

181.4

183.2185.0

186.8188.6

149

154160

166

171177

182188

300

310

320

330

340350

360

370

572

590608

626

644662

680698

-13.3

-12.8

-12.2

-11.7-11.1

-10.6

-10.0

-9.44

8

9

10

11

12

13

14

15

46.4

48.2

50.0

51.853.6

55.4

57.2

59.0

8.89

9.44

10.0

10.611.1

11.7

12.2

12.8

48

49

50

51

52

53

54

55

118.4

120.2

122.0

123.8125.6

127.4

129.2

131.0

31.1

31.7

32.2

32.833.3

33.9

34.4

35.0

88

89

90

91

92

93

94

95

190.4

192.2

194.0

195.8197.6

199.4

201.2

203.0

193

199

204

210216

221

227

232

380

390

400

410

420

430

440

450

716

734

752

770788

806

824

842

-8.89-8.33

-7.78

-7.22

-6.67

-6.11-5.56

-5.00

16

17

18

19

20

21

22

23

60.862.6

64.4

66.2

68.0

69.871.6

73.4

13.313.9

14.4

15.0

15.6

16.116.7

17.2

56

57

58

59

60

61

62

63

132.8134.6

136.4

138.2

140.0

141.8143.6

145.4

35.636.1

36.7

37.2

38

4349

54

96

97

98

99

100

110

120

130

204.8206.6

208.4

210.2

212

230248

266

238243

249

254

260

266271

277

460

470

480

490

500

510

520

530

860878

896

914

932

950968

986

-4.44

-3.89

-3.33-2.78

-2.22

-1.67

-1.11

-0.56

2425

26

27

28

29

30

31

75.2

77.0

78.880.6

82.4

84.2

86.0

87.8

17.8

18.3

18.919.4

20.0

20.6

21.1

21.7

6465

66

67

68

69

70

71

147.2

149.0

150.8152.6

154.4

156.2

158.0

159.8

60

66

7177

82

88

93

99

140150

160

170

180

190

200

210

284

302

320338

356

374

392

410

282

288

293299

304

310

316

321

540550

560

570

580

590

600

610

1004

1022

10401058

1076

1094

1112

1130

0

0.56

1.11

1.67

2.222.78

3.33

3.89

32

33

34

35

36

37

38

39

89.6

91.4

93.2

95.0

96.898.6

100.4

102.2

22.2

22.8

23.3

23.9

24.425.0

25.6

26.1

72

73

74

75

76

77

78

79

161.6

163.4

165.2

167.0

168.8170.6

172.4

174.2

104

110

116

121127

132

138

143

220

230

240

250

260

270

280

290

428

446

464

482500

518

536

554

327

332

338

343349

354

360

366

620

630

640

650

660

670

680

690

1148

1166

1184

12021220

1238

1256

1274

C. F. C. F. C. F. C. F.

371

377

382388

393399

404

410

700

710

720

730

740

750

760

770

1292

1310

13281346

13641382

1400

1418

593

599

604610

616621

627

632

1100

1110

1120

1130

1140

1150

1160

1170

2012

2030

20482066

20842102

2120

2138

816

821

827832

838843

849

854

1500

1510

1520

1530

1540

1550

1560

1570

2732

2750

27682786

28042822

2840

2858

1038

1043

10491054

10601066

1071

1077

1900

1910

1920

1930

1940

1950

1960

1970

3452

3470

34883506

35243542

3560

3578

416

421

427

432

438443

449

454

780

790

800

810

820

830

840

850

1436

1454

1472

1490

15081526

1544

1562

638

643

649

654

660666

671

677

1180

1190

1200

1210

1220

1230

1240

1250

2156

2174

2192

2210

22282246

2264

2282

860

866

871

877

882888

893

899

1580

1590

1600

1610

1620

1630

1640

1650

2876

2894

2912

2930

29482966

2984

3002

1082

1088

1093

1099

11041110

1116

1121

1980

1990

2000

2010

2020

2030

2040

2050

3596

3614

3632

3650

36683686

3704

3722

460

466

471

477

482

488

493

499

860

870

880

890

900

910

920

930

1580

1598

1616

1634

1652

1670

1688

1706

682

688

693

699

704

710

716

721

1260

1270

1280

1290

1300

1310

1320

1330

2300

2318

2336

2354

2372

2390

2408

2426

904

910

916

921

927

932

938

943

1660

1670

1680

1690

1700

1710

1720

1730

3020

3038

3056

3074

3092

3110

3128

3146

1127

1132

1138

1143

1149

1154

1160

1166

2060

2070

2080

2090

2100

2110

2120

2130

3740

3758

3776

3794

3812

3830

3848

3866

504510

516521

527

532

538

543

940950

960

970

980

990

1000

1010

17241742

17601778

1796

1814

1832

1850

727732

738743

749

754

760

766

13401350

1360

1370

1380

1390

1400

1410

24442462

24802498

2516

2534

2552

2570

949954

960966

971

977

982

988

17401750

1760

1770

1780

1790

1800

1810

31643182

32003218

3236

3254

3272

3290

11711177

11821188

1193

1199

1204

1210

21402150

2160

2170

2180

2190

2200

2210

38843902

39203938

3956

3974

3992

4010

549

554

560

566

571577

582

588

1020

1030

1040

1050

1060

1070

1080

1090

1868

1886

1904

1922

19401958

1976

1994

771

777

782

788

793799

804

810

1420

1430

1440

1450

1460

1470

1480

1490

2588

2606

2624

2642

26602678

2696

2714

993

999

1004

1010

1016

1021

1027

1032

1820

1830

1840

1850

1860

1870

1880

1890

3308

3326

3344

3362

3380

3398

3416

3434

1216

1221

1227

1232

1238

1243

1249

1254

2220

2230

2240

2250

2260

2270

2280

2290

4028

4046

4064

4082

4100

4118

4136

4154

Page 39



USEFUL FORMULAS

MECHANICAL FORMULAS

Torque in Lb.-ft. = RPM

Hp 5250× Hp =

5250

RPM Torque×

Rpm = Polesof No

Frequency .

120×

Horsepower =12000,33

)(2)(

×

××× RPM inches R pounds P π

Horsepower =000,63

RPM R P ×× or

000,63

RPM Torque×

1 KW = 1.341 HP 1 HP = 0.7457 KW

TORQUE (LB.-IN.) AT 1 HP

RPM LB.-IN RPM LB.-IN RPM LB.-IN RPM LB.-IN

17501430

1170950870780640580520420

3644

5466728198109121150

350280

230190155125100846856

180225

2743314065046307509261125

4537

302520

16.513.5119

7.5

14001703

21002520315038184667572770008400

64.7

4.03.22.72.21.81.51.21.0

1050013404

1575019687233702863635000420005250063000

To compute torque at any horsepower, multiply torque values above by horsepower required.Examples: 10 hp @ 350 rpm, Torque = 10 x 180 or 18000 lb.-in.

½ hp @ 30 rpm, Torque = ½ x 2100 or 1050 lb.-in.

For intermediate speeds, approximate the torque from table, or apply standard torque formula above.

ELECTRICAL FORMULAS

Alternating Current

To Find Single-phase Three-phase

Amperes whenhorsepower is known pf Eff E

Hp

××

× 746

pf Eff E

Hp

×××

×

73.1

746

Amperes whenkilowatts are known pf E

Kw

×

×1000

pf E

Kw

××

×

73.1

1000

Amperes whenkva are known E

Kva 1000×

E

Kva 1000×

Kilowatts1000

pf E I ××

1000

73.1 pf E I ×××

Kva1000

E I ×

1000

73.1 E I ××

Horsepower –(output) 1000

pf Eff E I ×××

1000

73.1 pf Eff E I ××××

I = Amperes; E = Volts; Eff. = Efficiency; pf= Power factor; Kva = Kilovolt-amperes; Kw = Kilowatts

RULES OF THUMB (Approximation) At 1800 rpm, a motor develops 3 lb.-ft. per hp At 1200 rpm, a motor develops 4.5 lb.-ft. per hpAt 575 volts, a 3-phase motor draws 1 amp per hp At 460 volts, a 3-phase motor draws 1.25 amp per hpAt 230 volts, a 3-phase motor draws 2.5 amp per hp At 230 volts, a single-phase motor draws 5 amp per hp

At 115 volts, a single-phase motor draws 10 amp per hp

Page 40



WEIGHTS OF VARIOUS MATERIALS

Material

Average per cubic

foot in pounds

Material

Average per cubic

foot in pounds

BrickCommon

Cements

Portland

Coal and Coke

AnthraciteBituminousCharcoal

Coke

Concrete

Cement, fine

Rubble, coarse

Earth

Loam, dry, loose

Loam, packedLoam, soft loose mudLoam, dense mud

Gravel

Dry, packedWet, packed

Lime

Quick, loose lumpsQuick, fineStone, large rocks

Stone, irregular lumps

Masonry

Dry

Granite or limestoneMortar, rubbleSandstone, dressed

Metals

AluminumBrass, castBronzeCopper, cast

Copper, rolled or wireIron, gray cast

Iron, white castIron, wrought

100

94

6049

18.5

26.3

137

119

76

95108125

118130

5375

168

96

138

165154144

166524

548537

555445475490

Metals (Cont’d)Lead, cast

Lead, rolled NickelSteel, castSteel, rolled

Steel, stainlessTin, castZinc, cast

Oils

CrudeEngineGasoline

Petroleum

Refractory Materials

Firebrick, insulating

Firebrick material(superplastic)

Fireclay brick(superduty)

Ganister, ground silicaMagnesite and magnesite-

chrome brickMagnesite (loose)

Silica brick

Sand

Dry, loose

Dry, packed

Water

At 39.2°F (Max density)

Woods, Dry

HemlockHickory

IronwoodMahogany

MapleOak, liveOak, white

Pine, whitePine, yellow northernPine, yellow southernSpruce

708711537490495

473 - 516455443

485543

55

30 - 60

135

137 - 154

123

170 - 197155

102 - 115

100

110

62.425

25

53114

35 - 53495950

25344525

Page 41



PRESSURE EQUIVALENTS

Ounces per

Sq. In.

Lbs per

Sq. In.

Inchesof

Water

Millimetersof

Water

Inchesof

Mercury

Millimetersof

Mercury

0.250.50

1

23

4

56

7

89

101112

13

14

1516

17

1819

20

2122

23

24

2526

27

2829

30

31

3233

3435

0.0160.031

0.062

0.1250.187

0.250

0.3120.375

0.437

0.5000.562

0.6250.6870.750

0.812

0.875

0.9371.000

1.062

1.1251.187

1.250

1.3121.375

1.437

1.500

1.5621.625

1.687

1.7501.812

1.875

1.937

2.0002.062

2.1252.187

0.4330.866

1.732

3.4645.20

6.92

8.6610.39

12.12

13.8615.59

17.3219.0520.78

22 52

21 25

25 9827 71

29.44

31.1832.91

34.64

36.3738.10

39.84

41.57

43.3045.00

46.8

48.550.2

52.0

53.7

55.457.2

58.960.6

11.0022.00

44.00

88.0132.0

176.0

220.0264.0

308.0

350.9395.0

439.0483.0527.0

571

615

659703

747

791835

879

923967

1011

1055

10991143

1187

12311275

1319

1363

14071451

14951539

0.03190.0638

0.1275

0.25510.3826

0.570

0.6380.765

0.893

1.0201.148

1.2751.4031.531

1.658

1.786

1.9132.041

2.169

2.2962.424

2.551

2.6792.806

2.934

3.061

3.1893.317

3.444

3.5723.699

3.827

3.954

4.084.21

4.344.46

0.8101.621

3.239

6.4789.72

12.95

16.1919.43

22.67

25.9129.15

32.3835.6238.86

42.1

45.3

48.651.8

55.1

58.361.5

64.8

68.071.2

74.5

77.7

81.084.2

87.4

90.793.9

97.2

100.4

103.6106.9

110.1113.3

Page 42



METRIC EQUIVALENTS(Based on National Bureau of Standards)

LENGTH

cm = 0.3937 in. in. = 2.5400 cmm = 3.2808 ft. ft. = 0.3048 m

m = 1.0936 yd. yd. = 0.9144 mkm = 0.6213 mile mile = 1.6093 km

AREA

cm2 = 0.1549 in.

2 in.

2 = 6.4516 cm

2

m2 = 10.7638 ft.

2 ft.

2 = 0.0929 m

2

m2 = 1.1959 yd.

2 yd.

2 = 0.7645 m

2

km2 = 0.3861 mi.

2 mi.

2 = 2.5900 km

2

hectare = 2.471 acres acres = 0.4047 hectareone hectare = 10,000 m

2

VOLUMEcm

3 = 0.0610 in.

3 in.

3 = 16.3871 cm

3

m3 = 35.3142 ft.

3 ft.

3 = 0.0283 m

3

m3 = 1.3079 yd.

3 yd.

3 = 0.7645 m

3

Liter = 0.0353 ft.3

ft.3

= 28.32 liters

Liter = 0.2641 gal. (U.S.) gal. = 3.7853 liters

Liter = 61.0250 in.3 in.

3 = 0.0163 liters

one Liter of pure water @ 4°C = 2.2046 lb. = 1 kg

WEIGHT g = 15.4323 grains grain = 0.0647 g

g = 0.0352 oz. oz. = 28.3496 gkg = 2.2046 lbs. lb. = 0.4535 kg

kg = 0.0011 ton (short) ton (short) = 907.1848 kgm ton = 1.1023 ton (short) ton (short) = 0.9071 m ton

m ton = 2205 lbs. ton (long) = 1016 kg

PRESSURE 1 kg per cm

2 = 14.22 lb. per in.

2 1 lb. per in.

2 = 0.07031 kg per cm

2

1 kg per m2 = 0.2048 lb. per ft.

2 1 lb. per ft.

2 = 4.882 kg per m

2

1 kg per cm2 = 0.9678 normal atmosphere

1 normal atmosphere = 1.0332 kg per cm2

1 normal atmosphere = 14.70 lb. per in.2

MISCELLANEOUS Density = 1 lb./ft.

3 = 16.0185 kg/m

3

Energy = 1 BTU = 0.252 kg-calorie

Work = 1 ft. lb. = 0.13826 kg-m

Density = 1 KW = 14.3328 kg-Cal/min.

Page 43



CONVERSION FACTORS

BTU per min. x 0.02356 = HorsepowerBTU per min. x 0.01757 = Kilowatts

Ft. Lbs. per min. x 0.0000303 = HorsepowerHorsepower x 42.44 = BTU per min

Horsepower x 33,000 = Ft. Lbs. per minHorsepower x 10.70 = kg cal per min.

Horsepower x 745.7 = WattsWatts x 0.7373 = Ft. Lbs. per sec.

Kilowatts x 1.3410 = HorsepowerInches of Water x 0.5773 = Oz. per Sq. In.

Oz. per Sq. In. x 1.732 = In. of WaterIn. of Water x 0.03613 = P.S.I.U.S. Gallons x 0.8327 = Imperial GallonsU.S. Gallons x 0.1337 = Cubic Ft.

In. of Mercury x 0.4912 = P.S.I.Ft. of Water x 0.4335 = P.S.I.Cu. Ft. x 62.428 = Pounds of WaterU.S. Gallons x 8.336 = Pounds of Water

BTU per Lb. x 0.586 = KWH per Ton (Short)

Cal per g x 1.8 = BTU per Poundg per cm x 62.428 = Pounds per Ft.M.P.H. x 88 = Ft. per Sec.Diameter Circle x 0.886 = Side of Equal Square

Side of Square x 1.414 = DiagonalSide of Cube x 1.732 = Space DiagonalJoule x 0.7373 = Foot PoundsMiles x 5,280 = Feet

Long Tons x 2,240 = PoundsAcres x 43,560 = Sq. Ft.Lbs. x 7,000 = Grains

POWER1 KW = 56.87 BTU per min.

1 KW = 1.341 HP1 HP = 550 Ft.-Lb. per sec.

1 Watt = 44.25 Ft.-Lb. per min.

1 Watt = 14.34 g-cal per min.

TEMPERATURE SCALESDegrees Fahrenheit = 1.8 (Deg C) + 32

Degrees Kelvin = Deg C + 273.16

Degrees Rankine = Deg F + 459.69

ENERGY1 BTU = 252.161 Calories

1 HP-HR = 2544.48 BTU

1 KWH = One KW for one our1 KWH = 2,655,218 Ft.-Lb.

1 KWH = 1.34 HP-HR

1 KWH = 3412.19 BTU

COST OF OPERATING ELECTRIC MOTORSOne KWH is consumed for each one (1) HP used per hour. Calculate HP used per hour and multiply

by prevailing rate per KWH to get cost of operation.

(Above is based on a motor efficiency of 85% and average line loss.)

Page 44



INCHES TO MILLIMETERS

Inches Millimeters Inches Millimeters Inches Millimeters

1/64 0.3969 9/16 14.2875 8 203.200

1/32 0.7938 37/64 14.6844 9 228.600

3/64 1.1906 19/32 15.0813 10 254.000

1/16 1.5875 39/64 15.4781 11 279.400

5/64 1.9844 5/8 15.8750 12 304.800

3/32 2.3813 41/64 16.2719 13 330.200

7/64 2.7781 21/32 16.6688 14 355.600

1/8 3.1750 43/64 17.0656 15 381.000

9/64 3.5719 11/16 17.4625 16 406.400

5/32 3.9688 45/64 17.8594 17 431.800

11/64 4.3656 23/32 18.2563 18 457.200

3/16 4.7625 47/64 18.6531 19 482.60013/64 5.1594 3/4 19.0500 20 508.000

7/32 5.5563 49/64 19.4469 21 533.400

15/64 5.9531 25/32 19.8438 22 558.800

1/4 6.3500 51/64 20.2406 23 584.200

17/64 6.7469 13/16 20.6375 24 609.600

9/32 7.1438 53/64 21.0344 Feet Meters

19/64 7.5406 27/32 21.4313 3 0.9144

5/16 7.9375 55/64 21.8281 4 1.2192

21/64 8.3344 7/8 22.2250 5 1.5240

11/32 8.7313 57/64 22.6219 6 1.8288

23/64 9.1281 29/32 23.0188 7 2.1336

3/8 9.5250 59/64 23.4156 8 2.4384

25/64 9.9219 15/16 23.8125 9 2.7432

13/32 10.3188 61/64 24.2094 10 3.0480

27/64 10.7156 31/32 24.6063 20 6.0960

7/16 11.1125 63/64 25.0031 30 9.1440

29/64 11.5094 1 25.4000 40 12.1920

15/32 11.9063 2 50.8000 50 15.2400

31/64 12.3031 3 76.2000 60 18.28801/2 12.7000 4 101.600 70 21.3360

33/64 13.0969 5 127.000 80 24.3840

17/32 13.4938 6 152.400 90 27.4320

35/64 13.8906 7 177.800 100 30.4800

Page 45



MEASURES AND WEIGHTS

DECIMAL OF AN INCH AND A FOOT

Fractions

Of Inch of Foot

I n c h E q u i v a -

l e n t s t o F

o o t

F r a c t i o n

s

Fractions

Of Inch of Foot


l e n t s t o F

o o t

F r a c t i o n

s

Fractions

Of Inch of Foot


l e n t s t o F

o o t

F r a c t i o n

s

Fractions

Of Inch of Foot


l e n t s t o F

o o t

F r a c t i o n

s

0.0052 1/16 0.2552 3 1/16 0.5052 6 1/16 0.7552 9 1/160.0104 1/8 0.2604 3 1/8 0.5104 6 1/8 0.7604 9 1/8

1/64 0.015625 3/16 17/64 0.265625 3 3/16 33/64 0.515625 6 3/16 49/64 0.765625 9 3/160.0208 1/4 0.2708 3 1/4 0.5208 6 1/4 0.7708 9 1/40.0260 5/16 0.2760 3 5/16 0.5260 6 5/16 0.7760 9 5/16

1/32 0.03125 3/8 9/32 0.28125 3 3/8 17/32 0.53125 6 3/8 25/32 0.78125 9 3/80.0365 7/16 0.2865 3 7/16 0.5365 6 7/16 0.7865 9 7/160.0417 1/2 0.2917 3 1/2 0.5417 6 1/2 0.7917 9 1/2

3/64 0.046875 9/16 19/64 0.296875 3 9/16 35/64 0.546875 6 9/16 51/64 0.796875 9 9/160.0521 5/8 0.3021 3 5/8 0.5521 6 5/8 0.8021 9 5/80.0573 11/16 0.3073 3 11/16 0.5573 6 11/16 0.8073 9 11/16

1/16 0.06250 3/4 5/16 0.31250 3 3/4 9/16 0.56250 6 3/4 13/16 0.81250 9 3/40.0677 13/16 0.3177 3 13/16 0.5677 6 13/16 0.8177 9 13/160.0729 7/8 0.3229 3 7/8 0.5729 6 7/8 0.8229 9 7/8

5/64 0.078125 15/16 21/64 0.328125 3 15/16 37/64 0.578125 6 15/16 53/64 0.828125 9 15/160.0833 1 0.3333 4 0.5833 7 0.8333 100.0885 1 1/16 0.3385 4 1/16 0.5885 7 1/16 0.8385 10 1/16

3/32 0.09375 1 1/8 11/32 0.34375 4 1/8 19/32 0.59375 7 1/8 27/32 0.84375 10 1/80.0990 1 3/16 0.3490 4 3/16 0.5990 7 3/16 0.8490 10 3/160.1042 1 1/4 0.3542 4 1/4 0.6042 7 1/4 0.8542 10 1/4

7/64 0.109375 1 5/16 23/64 0.359375 4 5/16 39/64 0.609375 7 5/16 55/64 0.859375 10 5/160.1146 1 3/8 0.3646 4 3/8 0.6146 7 3/8 0.8646 10 3/80.1198 1 7/16 0.3698 4 7/16 0.6198 7 7/16 0.8698 10 7/16

1/8 0.12500 1 1/2 3/8 0.37500 4 1/2 5/8 0.62500 7 1/2 7/8 0.87500 10 1/20.1302 1 9/16 0.3802 4 9/16 0.6302 7 9/16 0.8802 10 9/160.1354 1 5/8 0.3854 4 5/8 0.6354 7 5/8 0.8854 10 5/8

9/64 0.140625 1 11/16 25/64 0.390625 4 11/16 41/64 0.640625 7 11/16 57/64 0.890625 10 11/160.1458 1 3/4 0.3958 4 3/4 0.6458 7 3/4 0.8958 10 3/40.1510 1 13/16 0.4010 4 13/16 0.6510 7 13/16 0.9010 10 13/16

5/32 0.15625 1 7/8 13/32 0.40625 4 7/8 21/32 0.65625 7 7/8 29/32 0.90625 10 7/80.1615 1 15/16 0.4115 4 15/16 0.6615 7 15/16 0.9115 10 15/160.1667 2 0.4167 5 0.6667 8 0.9167 11

11/64 0.171875 2 1/16 27/64 0.421875 5 1/16 43/64 0.671875 8 1/16 59/64 0.921875 11 1/160.1771 2 1/8 0.4271 5 1/8 0.6771 8 1/8 0.9271 11 1/80.1823 2 3/16 0.4323 5 3/16 0.6823 8 3/16 0.9323 11 3/16

3/16 0.18750 2 1/4 7/16 0.43750 5 1/4 11/16 0.68750 8 1/4 15/16 0.93750 11 1/40.1927 2 5/16 0.4427 5 5/16 0.6927 8 5/16 0.9427 11 5/160.1979 2 3/8 0.4479 5 3/8 0.6979 8 3/8 0.9479 11 3/8

13/64 0.203125 2 7/16 29/64 0.453125 5 7/16 45/64 0.703125 8 7/16 61/64 0.953125 11 7/160.2083 2 1/2 0.4583 5 1/2 0.7083 8 1/2 0.9583 11 1/20.2135 2 9/16 0.4635 5 9/16 0.7135 8 9/16 0.9635 11 9/16

7/32 0.21875 2 5/8 15/32 0.46875 5 5/8 23/32 0.71875 8 5/8 31/32 0.96875 11 5/80.2240 2 11/16 0.4740 5 11/16 0.7240 8 11/16 0.9740 11 11/160.2292 2 3/4 0.4792 5 3/4 0.7292 8 3/4 0.9792 11 3/4

15/64 0.234375 2 13/16 31/64 0.484375 5 13/16 47/64 0.734375 8 13/16 63/64 0.984375 11 13/160.2396 2 7/8 0.4896 5 7/8 0.7396 8 7/8 0.9896 11 7/80.2448 2 15/16 0.4948 5 15/16 0.7448 8 15/16 0.9948 11 15/16

1/4 0.25000 3 1/2 0.50000 6 3/4 0.75000 9 1 1.00000 12

Page 46



INDEXAir, dry, properties of 38

Air, Humidity percentages 16

Atomic weights 34

Circles, area and circumstances 47

Coke consumption due to moisture 17

Color scale for temperatures 33Combustion, air required for 12,13

Combustion, useful data 23

Conversion factors 44

Crane Speeds 30

Crane hoisting rope, size and strength 31

Cupolas, formula for estimating height of bed coke 15

Cupolas, front slagging 11

Cupolas, melting rates for lined 4

Cupolas, melting rates for liningless hot blast 5

Cupolas, planning new installations 2

Cupolas, operation, pointers on 3

Cupolas, recommended tap hole sizes 10

Cupolas well, holding capacities 15

Cupolas lining data 6, 7, 8, 9

Decimal equivalents 46

Electric Arc furnace transformers 19

Electrical motors, cost of operating 44

Electrodes, Graphite 19

Energy 44

Formulas, mechanical, electrical, rules of thumb 40

Fusion, points, ash and slag 33

Gases and vapors, physical properties 37

Hydro-Arc furnace data, power consumption 20

Hydro-Arc furnace, Shell capacities 18

Inches to Millimeters 45

Induction furnace, vertical type 21

Induction furnace, horizontal type 22Ladles, capacities, iron 26

Ladles, capacities, steel 27

Ladles, selecting size of U-ladles 24

Ladles, capacities of U-Ladles 25

Ladles, method of calculating capacities 29

Ladles, standard spout arrangements 25

Magnets, scrap handling, lifting capacities 32

Malleable iron, grades 33

Metal densities in molten state 29

Melting points, minerals and oxides 33

Metal temperature and melting ratio 14

Metric equivalents 43

Monolithic linings 10Power 44

Pressure equivalents 42

Properties of metals and alloys 35

Temperature, conversion 39

Temperature, cupola tapping 28

Temperature scales 44

Thermal properties, metals 36

Weights, various materials 41

Page 48



Indexing Vibrating Feeder Type Cupola Charge

133 Cu. Ft. Clamshell Charging Bucketfor Loading Vibrating Feeder Cupola Charger

Size 18’/19’/18’ WhitingHydro-Arc Electric Furnace

Pictured on these pages are a number of reasons why – when planning to mechanize orimprove your foundry operations – you should consult Whiting. No matter what your problem,

there is Whiting foundry equipment to solve it – better and more economically.



50 Cu. Ft. Tilting Weigh Hopper Weighing CuCharges and Loading them into Skip Hoist Bu

Cupola Being Charged by Vibrating Feeder

170 Cu. Ft. Charging Bucket and “S” Type SkCupola ChargingSize 11’ Whiting Hydro-Arc Electric Furnace



35 Ton A.O.D.

Vessel

Trambeam HotMetal Carrier



50 Cu. Ft. Clamshell Arc Furnace Charging BucketSelf-Propelled Radio Controlled Transfer/Scale Car

10 Ton Charge Make-up Crane

80 Ton Channel Induction Holding Furnace



WHITING

metal shop - foundry_handbook

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