2018 Advanced Cupola Concepts Seminar

Coshocton Village Inn & Suites
October 10, 2018


Would you like:

  • The opportunity to discuss cupola issues and operations beyond the basics?
  • To learn how to further reduce variations and improve the consistency and quality of the iron you melt?
  • To gain a more in-depth knowledge and understanding of all-things cupola?

Then join us for this one-day seminar with leading experts in the field who will teach you well beyond the basics of your cupola operation.


  • Coshocton Village Inn & Suites
  • Coschocton, Ohio
  • October 10, 2018
Get Directions

Hotel Information

Village Inn
  • Coshocton Village Inn & Suites
  • Coschocton, Ohio
  • Standard Two Queens: $94.95/night; King Suite: $99.95/night

Group Reservation Number:  
Phone: 774-622-9455

Group Name:  
While making your reservation, please reference the group name: American Foundry Society.


  • Complimentary Deluxe Continental Breakfast (specific hours daily)
  • 24-hour Sweet shop
  • Free WIFI throughout the hotel
  • Business Center
  • Free outdoor parking

Room Block Release Date: 
Reservations must be received before September 10, 2018 (the Cut-Off Date).  At the cutoff the hotel will review the reservation pickup and release any unreserved rooms for general sale.  Room reservations made after the cutoff date will be made on a space- and rate-available basis at the AFS group rate after this date.

Cancellation Policy:
Cancellations must be received no later than 6:00 p.m. the day of arrival.  Past 6:00 p.m. your credit card will be charged along with the 13.25 tax percent.

Travel Information

Airport/Hotel Transportation:
Nearby Airports:

  • Richard Downing Airport – 5 miles
  • Akron – Canton Airport – 90 miles
  • Cleveland Hopkins International – 127 miles
  • Port Columbus International – 77 miles 

The downtown business district of Coshocton is also located within minutes of our hotel, as are a variety of restaurants and places to shop. Equally accessible are many towns, suburbs and major cities from SR 83, SR 16, and US 36 to I-77.

Conference Agenda

Tuesday, October 9, 2018
6 p.m.
Evening Reception

Coshocton Village Inn and Suites, Coshocton, OH

Wednesday, October 10, 2018
7:30 - 7:45 a.m.
Opening Remarks & Introductions

Pete Satre (Moderator) 
Allied Mineral Products, Columbus, OH

  • State of the “Cupola Union” address
7:45 - 9:45 a.m.
Fundamentals Of Cupola Design & Function

David Kasun

Kuttner LLC, Port Washington, WI                               

  • Controls & data management
  • Recuperation, gas cooling, filtration technologies
  • Heat recovery/renewable resource waste heat reclamation
  • Design variations and cupola zones
  • Combustion and metallurgical reactions
  • Mass-energy balance principles, heat transfer and charge materials sizing
  • Effects of hot blast temperature, oxygen injection and humidity
  • Tuyere arrangement & design, water cooling considerations 
  • Dam height, slag layer depth and hearth pressure effects
  • Slag chemistry, fluxing and slag rates
  • Engineering calculations and efficiency metrics
  • New technologies
9:45 - 10 a.m.
10 - 11:15 a.m.
Refractory- Best Practices, High Performance & Long Campaign

Brent Buchcuski

United Refractories, Iron Mountain, MI

Angelo Petruccelli

Allied Mineral Products, Columbus, OH

  • History, overview, and best practices
  • Taphole and separator installation and repair
  • Bottom material, extended campaigns
  • Mechanical & thermal properties
  • High temperature chemical reactions
  • Specialty refractories and selection
  • New concepts for extended refractory campaigns
  • Cooling systems, monitoring and predictive maintenance for extended life
11:15 a.m. - Noon
Charge Composition & Metallurgy

Dan Weiskopf

Neenah Foundry Co, Neenah, WI 

  • Metallics – selection, quality, variations, cost, trials
  • Charge alloy selection & performance
  • Injection alloys selection and application
  • Contaminants and control
  • Coke optimization        
  • Flux calculations, determining carbon pickup and alloy loss
  • Basic charge and least cost charge calculation
Noon – 1 p.m.
1 - 1:30 p.m.
Cupola Safety

Alex Croll

Waupaca Foundry, Tell City, IN
Backup cooling systems, tap out and safety tuyere practices
CO and oxygen hazards for personnel and equipment
Water hazards, drop area and housekeeping
PPE selection and use
Drain and drop practices
Training programs and safety checklists

1:30 - 3 p.m.
Cupola Operation

Lyle Heberling

Iron Casting Research Institute, Columbus, OH 
Bruce Blatzer

Consultant, Columbus, OH

  • Iron and slag control, sampling and testing
  • HMI & data management/logging
  • Cupola operation relationships to chemistry and temperature
  • Optimizing costs, special charges, transition charges
  • Recordkeeping, monitoring, and automation
  • Cupola stack gas analysis and measurement
  • Understanding coke combustion/melting efficiency/offgas and coke utilization
3 - 3:15 p.m.
3:15 - 4:30 p.m.
Metallurgical & Operational Troubleshooting

Gene Ritchie

Ritchie Melting Consulting, Greenwood, IN
Charley Graf

Miller and Company, Danville, IL

  • Responding to chemistry variations
  • Tuyere and shell failures and response
  • Dealing with a runout
  • Taphole blowing, back pressure
  • Reacting to refractory problems
4:30 - 5 p.m.
Q&A-Open Discussion

All speakers and students

5 p.m.
Seminar Concludes
Thursday, October 11, 2018
8 a.m.
Plant Tour Followed By Cupola Committee Meeting

Special Events


Registration Fees

AFS Member $425

Non-AFS Member $595

Cancellations & Substitutions

Substitutions will be accepted anytime. However, cancellations of confirmed registrants with full refund of fees will not be accepted unless received at least two weeks prior to the conference date. In the unlikely event the conference is cancelled for any reason, AFS liability is limited to the return of the registration fee.