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Ductile-iron-foundry gets help when coke prices skyrocket

By modifying proven technology, Air Products maximizes coke saving for a ductile iron foundry.

Issue: When coke prices hit record levels, Air Products specialists began looking for ways to help foundries stay competitive. Air Products identified an existing ductile iron foundry customer, that was technically progressive, had faith in Air Products’ technical ability, and could see the significant financial incentive in trying something a little different.

Solution: Air Products applications engineers worked to understand the specifics of the customer’s process and find a solution that was both technically and commercially suitable. An Air Products technologist drew upon the concepts of Air Products Cupola Oxygen System (APCOS), a technology developed in Europe to inject revert materials into cupolas. One critically important aspect of this technology was that it could also reduce coke consumption. Air Products equipment and advanced technology teams built on the APCOS technology with the introduction of new supersonic nozzles to enhance the efficiency of oxygen and natural gas penetration to maximize coke savings. Working closely with the customer, and tapping into a network of foundry industry resources, the technology was successfully integrated in their process, yielding significant savings. The customer has been operating the system for close to two years and is now looking to expand their use of the technology.

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