APCOS™ Technology—Air Products Cupola Oxy-fuel System for Iron Production
APCOS™ technology (Air Products Cupola Oxy-fuel System) to help you increase flexibility, control and melt rate for your cupola-based iron foundry.
Melting and Refining for Iron and Steel
Industrial gases and cost-effective technologies for all of your melting and refining operations
Air Products understands the critical nature of industrial gas supply in iron and steelmaking operations, especially in melting and refining processes. We offer state-of-the-art modes of supply for industrial gases, including oxygen, nitrogen, argon, hydrogen, and carbon dioxide. However, what sets us apart is our technical knowledge and experience. Our researchers and applications engineers focus on efficient and economical use of our gases in your melting and refining processes to help you achieve your energy, quality, environmental, and operating cost goals.
Meeting Today’s Needs and Working Toward Future Solutions
Our team of industry and technology specialists can provide a wide range of engineering services and consultation to assist with all of your melting and refining processes, including:
- Technical and design expertise
- Data acquisition and process monitoring
- Process commissioning and optimization
- Safety training
Benefits you can realize from our offerings and expertise:
- Reliable, economic gas supply
- Lower gas and fuel consumption and cost through optimization
- Improved safety
- Increased productivity
- Better yield and product quality
- Reduced off-gas volumes and emissions
Ready to decarbonize your iron and steel production?
Air Products combines supply of industrial gases, applications technology and equipment with an experienced applications team to help realize your sustainability goals with turnkey decarbonization solutions. Integrating oxy-fuel, hydrogen, and/or carbon capture into your iron and steel production processes can vastly lower greenhouse gas emissions, helping you reach your sustainability targets.
Wherever you are on your decarbonization journey, we can help.
Offerings
Argon
Argon, an inert gas, is commonly used in applications across metals production operations to improve quality, and increase efficiency and yield.
Computational Fluid Dynamics (CFD) Modeling Services for Metals Production
Proven Computational Fluid Dynamics Modeling (CFD) capabilities enable you to evaluate and investigate ways to increase productivity and cut costs.
Distribution Control Equipment
State-of-the-art gas distribution systems (flow controls) for small to large metals production applications.
Nitrogen
Nitrogen is routinely used in applications across foundries, integrated and mini mills, specialty/stainless, and non-ferrous metals production operations.
Oxy-fuel Burner Systems for Metals Production
Air Products' oxy-fuel combustion systems allow metals production operations to heat and melt more quickly and efficiently at lower cost.
Oxygen
Oxygen can improve combustion through increased heat transfer, higher flame temperatures, and reduced volume of flue gases in metals production operations.
Process Monitoring and Control System
Air Products' Process Monitoring and Control System helps achieve consistent product quality, reduced defects, and improved process safety.
Cost-effective Gas Technologies to Improve Performance while Lowering Overall Costs
Download our Iron & Steel Gas Applications OverviewBlast Furnace
Air Products offers a range of gas-based technologies and a full line of industrial gases to assist with your blast furnace operation. Oxygen can be injected into the blast furnace to improve combustion and facilitate the supplemental injection of pulverized coal or natural gas to reduce coke costs. The optimal solution for your process depends on many factors, such as your existing blast furnace’s operating parameters, coke costs, and production goals. Our applications engineers can help you implement tailored systems to meet your specific needs.
Basic Oxygen Furnace (BOF)
Oxygen is injected into a BOF at high rates and pressures to refine and decarburize hot metal. We can help you optimize oxygen usage for your basic oxygen furnace operation and can provide you with the most economical mode of supply based on your consumption patterns.
Electric Arc Furnace (EAF)
Oxygen is routinely used in modern EAFs for decarburization, oxy-fuel assisted melting and carbon monoxide post combustion. Using oxygen in these applications can reduce tap-to-tap time and lower electrical consumption per ton of steel. We can help you optimize oxygen usage for your melting operation and can provide you with the most economical mode of supply based on your consumption patterns.
Iron Cupola
Air Products’ oxygen enhanced combustion solutions can help you achieve greater fuel efficiencies, increase production and melt rate, reduce coke rates, achieve more consistent melt chemistry and improve alloy recovery. The optimal solution for your process depends on many factors, such as your existing cupola’s operating parameters, production goals and the current market conditions. Our applications engineers can help you implement tailored systems to meet your specific needs.
Induction Furnace
If you want to boost production, our oxy-fuel systems can provide supplemental heating to rapidly melt the charge. The right solution for your process depends on many factors, such as your induction furnace’s operating parameters, production goals, and the current market conditions.
Alternative Ironmaking
Air Products’ oxygen-enhanced combustion technologies can help your DRI or other alternative ironmaking operations during gasification or partial oxidation by removing the burden of nitrogen contained in air. Our industry specialists can help you evaluate your technology options and the benefits of oxygen-enhanced combustion.
Iron Rotary Furnace
Proven Computational Fluid Dynamics Modeling Services for the Iron and Steel Industry
We have extensive in-house computational fluid dynamic (CFD) modeling service capabilities that can help when looking to improve melting and refining operations. Our services have helped enable iron and steelmakers to investigate and evaluate ways to increase productivity and cut costs without putting their production process at risk. Modeling studies provide quick, validated results along with recommendations for the type of system best for your operation.
Learn More
Advanced Clean Energy Laboratory—virtual Demonstrations to Global Locations
The Advanced Clean Energy Laboratory is our newest demonstration facility, capable of facilitating development and full-scale testing of combustion systems using actual customer fuels. Plus a remote video imaging system enables real-time participation in testing via the Internet.
Case Studies
- Updating cupola technology pays for itself in savings
- Soaking pit furnace sees outstanding savings
- Cupola operator re-thinks old coke substitution rates
- Getting to the right solution for a rotary hearth furnace
- Ductile-iron-foundry gets help when coke prices skyrocket
- RFQ analysis saves steel mills time and money
- Solving steel casting issues
Count on us...
Turn to Air Products to deliver reliable gas supply and cost-effective technologies.