Steel

Cupola furnaces are long-standing, proven equipment in the foundry industry, often referred to as “mini blast furnaces.” Using coke as fuel, they remelt pig iron and scrap. Raw materials are charged from the top of the furnace, preheated as they descend, and fully melted in the high-temperature combustion zone. The molten iron is refined and separated from slag before being tapped continuously or intermittently. While the process is mature, operators face mounting challenges: rising coke consumption, increasing production costs, and stricter environmental requirements. Messer’s Oxy Fuel combustion technology provides a reliable solution. By injecting high-purity oxygen or oxygen-enriched air through the tuyeres, coke burns more completely, flame temperatures increase significantly, and a stable reducing atmosphere is established above the combustion zone. This leads to faster, more efficient melting with improved process control. Combined with Messer’s proprietary OXIPYR® burner system, proven in decades of industrial use, oxygen penetrates deep into the charge bed, ensuring thorough combustion, uniform furnace heating, and reduced wear on refractory linings. The value of choosing Messer’s OXIPYR® system is clear: • Lower coke ratio – reduced fuel costs • Higher melting efficiency – faster reactions and higher furnace temperatures • Stable operations – consistent heat distribution and product quality • Greener production – lower emissions to meet stricter standards • Proven reliability – backed by global experience and local expertise

In modern steelmaking, ladle preheating is essential for ensuring process stability and consistent product quality. Conventional air-fuel combustion, however, faces inherent limitations: nitrogen present in the air lowers flame temperatures, reduces thermal efficiency, and leads to significant NOx emissions. This not only increases fuel consumption and operating costs but also places additional pressure on environmental compliance. Oxy Fuel combustion technology brings a step change to ladle preheating. By using pure oxygen instead of air as the oxidant, it enables much higher flame temperatures with more concentrated and efficient heat transfer. Ladles can reach the required temperature in a shorter time, fuel consumption is significantly reduced, and flue gas volumes drop considerably, with NOx emissions kept to a minimum. At the heart of this process lies Messer’s proprietary OXIPYR® burner. Specifically engineered for oxy-fuel applications, the OXIPYR® burner delivers a stable, high-temperature, and uniform flame, ensuring even heating of the ladle lining while avoiding localized overheating that can shorten refractory life. With its flexible control features, it allows for fast start-up and shut-down, adapting easily to different production schedules. Backed by decades of combustion expertise and global engineering know-how, Messer offers a complete solution for ladle preheating—covering gas supply, system design, and long-term service support. By adopting Messer’s oxy-fuel preheating technology, steelmakers benefit from: • Higher efficiency: shorter preheating times and faster production cycles; • Energy savings: reduced fuel consumption and lower operating costs; • Environmental performance: lower NOx emissions to meet stringent regulations; • Improved quality: stable steel temperature and more consistent casting; • Reliable operation: the proven performance of OXIPYR® burners supported by Messer’s service expertise.