Cupola Redesign 3D (Team Review)

Concept model, 2027 cupola redesign. Not final dimensions.

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Grate cartridge (Rev C) 2" refractory lining Sand bed + fiber board, 7° taper Cold plenum + blower riser Hot plenum, 3" blast duct, downlegs Burners (detail below) 1/2" braided oil trunk 3/8" SS oil branches Atomizing air Flame path Drag to rotate, scroll or pinch to zoom.

One of two identical burners. 2.0 mm siphon nozzle in a 3" burner tube with a front washer that tri-clamps to the 5" port, and a crimped back end the 3" blast duct elbow slips over. The port tube runs through the 18" shell tangentially, 5.5" off the well center, pitched 7° down, with a 1" refractory liner. Oil and air enter through a side boss. The heater is two black iron tees and a nipple running parallel to the burner tube, with the 300 W element threaded into the front tee. The 3/8" cold feed and the air line both come in level from the back. Hot oil leaves the front tee through a 1/2" close nipple into a 1/2" tee standing on end. A 3" stainless bimetal thermometer (0–250°F, 1/2" NPT back mount, 1-3/4" stem) threads into the top, dial facing up, stem pointing down into the oil stream. The oil leaves the bottom through a 1/2" × 1/4" bushing and elbow, then the needle valve and a second elbow into the boss; air runs through a ball valve. To remove: slide the duct off, open the tri-clamp, lift the burner out with everything attached.

Shell, 5" port, tri-clamp Refractory 3" burner tube, washer, boss 3" duct elbow Nozzle + adapter Black iron tee heater Element head Outlet thermometer Needle valve Ball valve Oil Air

Schematic of a typical internal-mix siphon air nozzle on its brass adapter. It shows the layout most of these nozzles share, not measured geometry: proportions are approximate and makers differ in how the inner parts are split up or pressed together. Compressed air comes in the back of the adapter on a 1/4" line and runs down the center tube, jetting out its tip into the mixing chamber. Oil comes in the top on a 1/8" line and fills the passage around the tube, where a distributor ring spreads it evenly. The air jet leaving the tube drops the pressure around its tip, and that draw pulls the oil down from the line into the mixing chamber with no pump (the siphon), where the air shears it into fine droplets before the mix leaves the exit orifice. Air pressure sets both how much oil gets drawn and how fine it breaks up.

Brass adapter Nozzle body and exit orifice Distributor ring Air tube Seal Air Oil Spray Drag to rotate, scroll or pinch to zoom.

Two 3" grates, each cast in its own 3" steel shell, then tack-welded together into a 6" cartridge with the plenum clamshells tacked on. Each grate has three 1" OD 304 tubes inside 3" octagon EZ Cubed 80-15 sleeves, with 1.25" slots, and the grates cross at 85°. Tube ends are cut flush with the shell OD, and the sleeves run full length into the side refractory. All castable faces get three coats of Asbury BoroKote Max. The plenum clamshells are 5" tall, centered on the 6" shell, leaving ½" of bare shell at top and bottom for the locating collars and joints.

EZ Cubed 80-15 sleeves and ring 1" OD 304 tube 11 ga cartridge shell, 18" ID Cold plenum Hot plenum Drag to rotate, scroll or pinch to zoom.