Various types of furnaces have been used for cast iron melting. In terms of tonnage, the primary melting methods used by iron casting facilities are cupola and induction furnaces. This article describes the operation and control principles of cupola furnace. It discusses the advantages of specialized cupolas such as cokeless cupola and plasma-fired cupola. Melting in iron foundries is a major application of induction furnaces. The article describes the operations of two induction furnaces: the channel induction furnace and the induction crucible furnace. It explains the teapot principle of pressure-actuated pouring furnaces and provides information on the effect of pouring magnesium-treated melts.

The crucible induction furnace is growing as an alternative melting unit to the cupola furnace due to its low specific power and reduced power consumption during solid melting material. This article details the process engineering features of the crucible induction furnace. It discusses the various processes involved in melting, holding, and pouring of liquid melt in crucible induction furnaces wherein the holding operation is carried out in channel furnace and pouring operation in pressure-actuated pouring furnaces. The article examines the behavior of furnace refractory lining to defects such as erosion, infiltration, crack formation, and clogging, and the corresponding preventive measures to avoid the occurrence of these defects. It elucidates the overall furnace operations, including commissioning, operational procedures, automatic process monitoring, inductor change, and dealing with disturbances.

This article focuses on the construction, operation of electric arc furnaces (EAF), and their auxiliary equipment in the steel foundry industry. It provides information on the power supply of EAF and discusses the components of the EAF, including the roof, furnace shell, spout and tap hole, water-cooling system, preheat and furnace scrap burners, and ladles. The article describes the acid and basic steelmaking practices. It discusses the raw materials used, oxidation process, methods of heat reduction, and deoxidation process in the practices. The article provides a discussion on the arc melting of iron and EAF steelmaking.

In high-iron-tonnage operations, the cupola remains the most efficient source of continuous high volumes of iron needed to satisfy high production foundries or the multiple casting machines of centrifugal pipe producers. This article explores successful improvement technologies in cupola equipment, including preheated air blast, recuperative hot blast systems, and duplex electric holders. It discusses the shell, intermittent or continuous tapping, tuyere and blower systems, refractory lining, water-cooled cupolas, emission-control systems, and storage and handling of the charge materials. The article provides a discussion on the control tests for cupola, including the chill test and mechanical test. It concludes with information on specialized cupolas such as the cokeless cupola and the plasma-fired cupola.