Comparative Analysis for Cost and Operational Differences Between Equivalent Cupola and Medium Frequency Furnace Melt Center Designs

摘要

A thorough analysis of the operating cost and operational differences between a 40 ton/hr cupola and a 40 ton/hr medium frequency melt center was performed. The cupola and electric furnace design models include realistic cost inputs for charge materials, labor, refractory, maintenance and energy to accurately estimate melt center operating costs and final iron cost on a per ton basis for a 4,000 hr/yr melt operation. Melt center model design assumptions include the use of high efficiency furnace and equipment with energy recovery equipment where applicable. Capital equipment cost estimates for complete greenfield melt center installations for each system were used to determine break even points for both scenarios. Tables and graphs make comparisons for significant operating parameters and operational costs. This analysis provides useful data and information for the typical foundry by providing operating benchmarks for optimal melt center designs.