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DESIGN, REFRACTORY, CHARGE MATERIAL & OPERATION
Gain expertise from experienced metalcasting
facilities and suppliers, including:
May 5-6, 2015 • American Cast Iron Pipe Company • Birmingham, AL
ES R
D U
LU TO
C T
IN AN
PL
Are your profits melting away?
Presented by the AFS 8F Cupola Committee
ABC Coke Drummond
Are your profits melting away?
ACIPCO
Allied Minerals
Learn and discuss best practices for
your cupola operation.
Auburn Labs
Charlotte Pipe & Foundry Co.
Basic Principles
Charge Materials
Refractory Systems
Operation
Preparing for Startup
Tapping Out
Hickman, Williams and Co.
ICRI
Kuttner
Reno Refractory
Representatives of the
AFS Cupola Committee (8F)
Waupaca Foundry
ADVOCATE. EDUCATE. INNOVATE.
U.S. Pipe
www.afsinc.org • 800/537-4237
May 5-6, 2015
American Cast Iron Pipe Company
Birmingham, AL
DESIGN, REFRACTORY, CHARGE MATERIAL & OPERATION
Registration Fees
 AFS Member $395 •  Non-AFS Member $595
Name____________________________________________________
AFS Membership # (if applicable)_____________________________
Title_____________________________________________________
Check enclosed 
Company_________________________________________________
Address__________________________________________________
Charge my :
American Express 
MasterCard 
Visa 
Card Number_____________________________________________
City/State/Zip_____________________________________________
Phone_______________________Fax_________________________
E-mail___________________________________________________
Expiration Date____________________________________________
Authorized Signature_______________________________________
RETURN FORM TO:
American Foundry Society, 35169 Eagle Way, Chicago, IL 60678-1351 Contact AFS Customer Service at 800/537-4237 Fax: 847/824-7848
For additional registrants, copy this form.
American Foundry Society
Class will be held at American Cast Iron Pipe Company, 1501 31st Ave North, Birmingham, AL 35207
1695 N. Penny Lane
Schaumburg, IL 60173
Hotel: Hotel accommodations will be at the discretion of the attendee. A list of area hotels can be supplied upon request.
Cancellations and Substitutions: Substitutions will be accepted any time. However, cancellations of confirmed registrants with full refund of fees cannot be
accepted unless received two weeks prior to conference date. In the unlikely event the conference is canceled for any reason, AFS liability is limited to the
return of the registration fee.
Tax Deduction of Expenses: An income tax deduction is allowed for expenses of education, including registration fee, travel, meals and lodging, undertaken
to maintain and improve professional skills (see U.S. Treasury Regulation 1:162.5).
DESIGN, REFRACTORY, CHARGE MATERIAL & OPERATION
Gain expertise from experienced metalcasting
facilities and suppliers, including:
May 5-6, 2015 • American Cast Iron Pipe Company • Birmingham, AL
ES R
D U
LU TO
C T
IN AN
PL
Are your profits melting away?
Presented by the AFS 8F Cupola Committee
ABC Coke Drummond
Are your profits melting away?
ACIPCO
Allied Minerals
Learn and discuss best practices for
your cupola operation.
Auburn Labs
Charlotte Pipe & Foundry Co.
Basic Principles
Charge Materials
Refractory Systems
Operation
Preparing for Startup
Tapping Out
Hickman, Williams and Co.
ICRI
Kuttner
Reno Refractory
Representatives of the
AFS Cupola Committee (8F)
Waupaca Foundry
ADVOCATE. EDUCATE. INNOVATE.
U.S. Pipe
www.afsinc.org • 800/537-4237
May 5-6, 2015
American Cast Iron Pipe Company
Birmingham, AL
DESIGN, REFRACTORY, CHARGE MATERIAL & OPERATION
Registration Fees
 AFS Member $395 •  Non-AFS Member $595
Name____________________________________________________
AFS Membership # (if applicable)_____________________________
Title_____________________________________________________
Check enclosed 
Company_________________________________________________
Address__________________________________________________
Charge my :
American Express 
MasterCard 
Visa 
Card Number_____________________________________________
City/State/Zip_____________________________________________
Phone_______________________Fax_________________________
E-mail___________________________________________________
Expiration Date____________________________________________
Authorized Signature_______________________________________
RETURN FORM TO:
American Foundry Society, 35169 Eagle Way, Chicago, IL 60678-1351 Contact AFS Customer Service at 800/537-4237 Fax: 847/824-7848
For additional registrants, copy this form.
American Foundry Society
Class will be held at American Cast Iron Pipe Company, 1501 31st Ave North, Birmingham, AL 35207
1695 N. Penny Lane
Schaumburg, IL 60173
Hotel: Hotel accommodations will be at the discretion of the attendee. A list of area hotels can be supplied upon request.
Cancellations and Substitutions: Substitutions will be accepted any time. However, cancellations of confirmed registrants with full refund of fees cannot be
accepted unless received two weeks prior to conference date. In the unlikely event the conference is canceled for any reason, AFS liability is limited to the
return of the registration fee.
Tax Deduction of Expenses: An income tax deduction is allowed for expenses of education, including registration fee, travel, meals and lodging, undertaken
to maintain and improve professional skills (see U.S. Treasury Regulation 1:162.5).
10:15 a.m.-12:00 p.m.
Refractory Systems
DESIGN, REFRACTORY, CHARGE MATERIAL & OPERATION
May 5-6, 2015 • American Cast Iron Pipe Company • Birmingham, AL
Presented by the AFS 8F Cupola Committee
Agenda
Tuesday, May 5 , 2015
th
3:00 p.m.-3:15 p.m.
8:00 a.m.-11:00 a.m.
Break
ACIPCo Foundry Plant Tour
3:15 p.m.-5:00 p.m.
11:30 a.m.-1:00 p.m.
Class Registration
1:00 p.m.-3:00 p.m.
Cupola Introduction Basic
Principles of Operation
David Kasun, Kuttner LLC
• Basic cupola theory introduction, general melting
principles
• Cupola design variations―Lined/unlined, hot/cold
blast, spout designs
• Cupola zones top gas, preheat, melting,
combustion, well, tap and siphon
• Coke combustion, Boudouaard reaction, gas
chemistry, oxidizing-reducing atmospheres
• Heat transfer in the cupola and charge material
sizing
• Thermal efficiency, combustion air demand
• Effects of hot blast temperature, oxygen injection
and humidity
• Tuyere arrangement, design, water cooling
• Iron dam height, slag layer depth and hearth
pressure effects
• Cupola geometry considerations blast ratio,
preheat time
• Slag rate and fluxing
• Cupola computer simulation
On-site registration will not be available.
Registration cut-off is April 29th, 2015.
You are invited to participate in
the next AFS 8F Cupola Committee
meeting to be held May 7th, 2015.
Contact Laura Kasch, AFS Technical Assistant,
847/824-0181 Ext. 246 for details.
Charge Make-Up and Melting
Zone Metallurgical Reactions
David Hughes, US Pipe & Foundry, Bessemer
David Kasun, Kuttner LLC
• Basic properties of charge materials
• Fundamental thermochemical reactions
• Iron superheating and Carbon pickup & Silicon
loss
• Slag chemistry, fluxing and slag rates
• Oxidation and reduction reactions, effects of gas
chemistry on metallurgy
• Well chemistry reactions
Charlie Hardin, Reno Refractories
Pete Satre, Allied Mineral Products
• Cupola Rebuild/Repair
• Inspecting and removing old refractory
• Taphole and Separator repair, Dam height control
• Bottom installation, Well Repair, Melt Zone
• Charge Zone, Dry-Out
10:00 a.m.-10:15 a.m.
John Berzsenyi, Waupaca Foundry
• Melting Down
• Special charges, skull prevention and gas
handling system considerations
• Charge changes, blast and oxygen settings
• Opening Drain Hole, blowing/cleaning cupola
• Bottom Drop, Safety Considerations
• Cupola interior inspection and recordkeeping
• Tuyere inspection, repair, record keeping
• Skull Removal and Repair
Preparing the Cupola for
Startup
Bart Barbee, Charlotte Pipe & Foundry
• Start-up checklist, tools, safety equipment, PPE,
procedures
• Bed coke selection, Coke light off and
measurement
• Safety tuyere operation, discharge and drop area
preparation
• Charging, startup special charges, Blast On
• Tap out procedures & safety (open vs. closed
taphole)
• Preparation for extended campaigns
• What to do when problems occur
Lyle Heberling, ICRI
Bill LaFramboise, Auburn Analytical Lab, Inc.
• Metallics: Steels, Cast irons, Pig iron,
Alternative materials
• Foundry Coke: Properties & Characteristics
• Alloys: Briquetted materials, Injection grades,
C, FeSi, SiC, FeMn
• Fluxes: Limestone, Calcium vs. Magnesium,
Fluorspar
Tapping Out Cupola,
Banking, Shutting Down
1:00 p.m.-2:00 p.m.
Wednesday, May 6th, 2015
Pete Satre, Allied Mineral Products
Ray Lewis, ABC Coke
Brian Johnson, Hickman Williams & Co.
3:45 p.m.-5:00 p.m.
Lunch
2:00 p.m.-3:30 p.m.
Charge Materials
Break
12:00 p.m.-1:00 p.m.
Questions and
Open Discussion
8:00 a.m.-10:00 a.m.
3:30 p.m.-3:45 p.m.
Questions and Open Discussion―
Roundtable Discussion
5:00 p.m.
Class Adjourned
Cupola Operation
• Chemistry Control―blast, oxygen, charge recipe,
spout additions
• Iron and slag testing
• Cupola operation relationships to chemistry and
temperature
• Slag Control―basicity, color, testing, quantity
• Optimizing the charge for conditions, special
charges, transition charges
• Least cost standard charge (consideration of
hidden costs and melt losses)
• Record keeping, reporting
• Automation and data collection, reporting
• Guidelines for troubleshooting
Thursday May 7, 2015
8F Committee Meeting and
Tyler-Union Plant Tour
The AFS 8F Cupola Technical Committee spring
meeting will be hosted by Tyler-Union Foundry,
Anniston, AL, the day after the cupola class. The
meeting will be held from 10:30 AM until 3:00 PM and
will include lunch. A tour of Tyler-Union will be given
beginning at 8:00 AM. Students and instructors from
the cupola class are welcome to attend the 8F tour
and meeting as guests. Please RSVP with AFS for
the tour and the 8F meeting at the time of registration
for the Practical Cupola Class.
Break
ADVOCATE. EDUCATE. INNOVATE.
www.afsinc.org • 800/537-4237
10:15 a.m.-12:00 p.m.
Refractory Systems
DESIGN, REFRACTORY, CHARGE MATERIAL & OPERATION
May 5-6, 2015 • American Cast Iron Pipe Company • Birmingham, AL
Presented by the AFS 8F Cupola Committee
Agenda
Tuesday, May 5 , 2015
th
3:00 p.m.-3:15 p.m.
8:00 a.m.-11:00 a.m.
Break
ACIPCo Foundry Plant Tour
3:15 p.m.-5:00 p.m.
11:30 a.m.-1:00 p.m.
Class Registration
1:00 p.m.-3:00 p.m.
Cupola Introduction Basic
Principles of Operation
David Kasun, Kuttner LLC
• Basic cupola theory introduction, general melting
principles
• Cupola design variations―Lined/unlined, hot/cold
blast, spout designs
• Cupola zones top gas, preheat, melting,
combustion, well, tap and siphon
• Coke combustion, Boudouaard reaction, gas
chemistry, oxidizing-reducing atmospheres
• Heat transfer in the cupola and charge material
sizing
• Thermal efficiency, combustion air demand
• Effects of hot blast temperature, oxygen injection
and humidity
• Tuyere arrangement, design, water cooling
• Iron dam height, slag layer depth and hearth
pressure effects
• Cupola geometry considerations blast ratio,
preheat time
• Slag rate and fluxing
• Cupola computer simulation
On-site registration will not be available.
Registration cut-off is April 29th, 2015.
You are invited to participate in
the next AFS 8F Cupola Committee
meeting to be held May 7th, 2015.
Contact Laura Kasch, AFS Technical Assistant,
847/824-0181 Ext. 246 for details.
Charge Make-Up and Melting
Zone Metallurgical Reactions
David Hughes, US Pipe & Foundry, Bessemer
David Kasun, Kuttner LLC
• Basic properties of charge materials
• Fundamental thermochemical reactions
• Iron superheating and Carbon pickup & Silicon
loss
• Slag chemistry, fluxing and slag rates
• Oxidation and reduction reactions, effects of gas
chemistry on metallurgy
• Well chemistry reactions
Charlie Hardin, Reno Refractories
Pete Satre, Allied Mineral Products
• Cupola Rebuild/Repair
• Inspecting and removing old refractory
• Taphole and Separator repair, Dam height control
• Bottom installation, Well Repair, Melt Zone
• Charge Zone, Dry-Out
10:00 a.m.-10:15 a.m.
John Berzsenyi, Waupaca Foundry
• Melting Down
• Special charges, skull prevention and gas
handling system considerations
• Charge changes, blast and oxygen settings
• Opening Drain Hole, blowing/cleaning cupola
• Bottom Drop, Safety Considerations
• Cupola interior inspection and recordkeeping
• Tuyere inspection, repair, record keeping
• Skull Removal and Repair
Preparing the Cupola for
Startup
Bart Barbee, Charlotte Pipe & Foundry
• Start-up checklist, tools, safety equipment, PPE,
procedures
• Bed coke selection, Coke light off and
measurement
• Safety tuyere operation, discharge and drop area
preparation
• Charging, startup special charges, Blast On
• Tap out procedures & safety (open vs. closed
taphole)
• Preparation for extended campaigns
• What to do when problems occur
Lyle Heberling, ICRI
Bill LaFramboise, Auburn Analytical Lab, Inc.
• Metallics: Steels, Cast irons, Pig iron,
Alternative materials
• Foundry Coke: Properties & Characteristics
• Alloys: Briquetted materials, Injection grades,
C, FeSi, SiC, FeMn
• Fluxes: Limestone, Calcium vs. Magnesium, Fluorspar
Tapping Out Cupola,
Banking, Shutting Down
1:00 p.m.-2:00 p.m.
Wednesday, May 6th, 2015
Pete Satre, Allied Mineral Products
Ray Lewis, ABC Coke
Brian Johnson, Hickman Williams & Co.
3:45 p.m.-5:00 p.m.
Lunch
2:00 p.m.-3:30 p.m.
Charge Materials
Break
12:00 p.m.-1:00 p.m.
Questions and
Open Discussion
8:00 a.m.-10:00 a.m.
3:30 p.m.-3:45 p.m.
Questions and Open Discussion―
Roundtable Discussion
5:00 p.m.
Class Adjourned
Cupola Operation
• Chemistry Control―blast, oxygen, charge recipe,
spout additions
• Iron and slag testing
• Cupola operation relationships to chemistry and
temperature
• Slag Control―basicity, color, testing, quantity
• Optimizing the charge for conditions, special
charges, transition charges
• Least cost standard charge (consideration of
hidden costs and melt losses)
• Record keeping, reporting
• Automation and data collection, reporting
• Guidelines for troubleshooting
Thursday May 7, 2015
8F Committee Meeting and
Tyler-Union Plant Tour
The AFS 8F Cupola Technical Committee spring
meeting will be hosted by Tyler-Union Foundry,
Anniston, AL, the day after the cupola class. The
meeting will be held from 10:30 AM until 3:00 PM and
will include lunch. A tour of Tyler-Union will be given
beginning at 8:00 AM. Students and instructors from
the cupola class are welcome to attend the 8F tour
and meeting as guests. Please RSVP with AFS for
the tour and the 8F meeting at the time of registration
for the Practical Cupola Class.
Break
ADVOCATE. EDUCATE. INNOVATE.
www.afsinc.org • 800/537-4237