Implementation of Metal Casting Best Practices - EERE - U.S. ...

More documents

Recommendations

Info

7.8 Installing Energy-Efficient Lighting Another simple activity a metal caster can perform to improve energy efficiency is to utilize energy-efficient ballasts, high-efficiency bulbs, and occupancy sensors in lighting systems. Although it may not make financial sense to replace all existing ballasts and bulbs at once, implementing a scheduled transition to more efficient equipment over time as existing equipment fails should be both feasible and beneficial. One of the facilities visited during this effort also had lighting turned on in areas where there was no one working. In fact, that lighting illuminated areas where workers seldom go. Facilities should consider installing occupancy sensors in such situations. An occupancy sensor will activate the light only when a worker enters the area. These devices are inexpensive and simple to install. 7.9 Transitioning to Cogged Belts Cogged belts are another simple item that a plant can incorporate into its energy plan. In beltdriven equipment, such as fans, it is best to use cogged belts rather than the traditional smooth belts. This is because the typical smooth belts slip and utilize more energy in turning the component. Utilizing cogged belts reduces slipping and improves the efficiency with which the component is turned, thus reducing its electrical demand. Although these belts are slightly more expensive than smooth belts, they both reduce energy consumption and last longer. 7.10 Scheduling Work during Non-Peak Power Rate Periods Finally, a facility’s energy management plan should incorporate scheduling energy-intensive processes to occur at the non-peak load periods. Performing such tasks at non-peak hours will reduce the demand on the local utility and allow the facility to take advantage of lower power rate charges. For example, many utilities will offer an overnight non-peak rate (e.g., from 9 p.m. to 7 a.m.), which could be $.02 per kWh less than the peak rate. Obviously, such varying rate structures make strategies such as performing melting during non-peak hours more cost effective. Steel Foundry-2 (page 52) worked with its utility to determine the most cost-effective schedule for melting with its electric arc furnaces. It was determined that the foundry could take advantage of non-peak loads if it performed its melting from 9:00 p.m. to 9:00 a.m. The facility adjusted its production and labor schedules accordingly and began performing melting operations within the prescribed time. Moving to this schedule resulted in an annual savings of $250,000 on the facility’s electricity bill. The cost to implement this change was minimal and primarily was associated with the need to rearrange production and labor schedules. There was no investment required in costly technology. Although such scheduling changes offer a simple solution to reducing energy costs, it is important that the facility adhere to the period of the non-peak loads. If the foundry turns on its 32
melters before the non-peak period, they will be charged the higher (i.e., peak) rate for the entire duration that the equipment is on. This practice has been witnessed in the field by Eppich Technologies, where the personnel in a melt shop were turning on their induction melting furnaces 10 minutes early to take advantage of an early labor break. This practice caused the facility to lose thousands of dollars each year because they were paying a much higher rate for their melting. Developing an energy management plan that properly schedules energy-intensive processes to take advantage of non-peak load rates and proactively examines immediately achievable, low- or no-cost opportunities can save a metal caster several thousands of dollars a year in operating costs. Utilizing energy-efficient equipment can save money without affecting plant operations or interfering with the product quality. A good energy management plan will reduce operating costs and improve a facility’s financial bottom line. 33
Page 2 and 3: Implementation of Metal Casting Bes
Page 4 and 5: Executive Summary Since 1995 the U.
Page 6 and 7: summarized comments regarding the t
Page 8 and 9: • Metal casters must investigate
Page 10 and 11: F. Iron Foundry-2..................
Page 12 and 13: As part of this project, an assessm
Page 14 and 15: 1.3 Report Organization This report
Page 16 and 17: energy needs, primarily to the larg
Page 18 and 19: As a result of this strategy, ITP h
Page 20 and 21: All of the facilities that particip
Page 22 and 23: A number of the facilities visited
Page 24 and 25: Steel Foundry Aluminum Foundry Alum
Page 26 and 27: 4. Methodology for Assessing Indust
Page 28 and 29: 5. Overall Assessment Observations
Page 30 and 31: samples and measurements from vario
Page 32 and 33: the Metalcasting Congress and other
Page 34 and 35: single in-line memory module (SIMM)
Page 36 and 37: application can offer tangible bene
Page 38 and 39: 7. Common Energy-Saving Solutions T
Page 40 and 41: 7.4 Installing Radiant Panels in Cr
Page 44 and 45: 8. Conclusion The ITP Metal Casting
Page 46 and 47: Appendix A: Plant Assessment Case S
Page 48 and 49: Scrap Rate The scrap rate at the pl
Page 50 and 51: Dross Management Metal dealers and
Page 52 and 53: B. Die Casting Plant-2 Plant Profil
Page 54 and 55: Quality Control The assessment team
Page 56 and 57: C. Steel Foundry-1 Plant Profile St
Page 58 and 59: also enables foundries to understan
Page 60 and 61: Automated Molding Line Steel Foundr
Page 62 and 63: D. Steel Foundry-2 Plant Profile St
Page 64 and 65: subsequent machining operations. Ex
Page 66 and 67: motor, with an older piece of equip
Page 68 and 69: 1. Implemented Best Practices Age S
Page 70 and 71: Treating Sand Iron Foundry-1 reclai
Page 72 and 73: F. Iron Foundry-2 Plant Profile Iro
Page 74 and 75: Working with the Utility Iron Found
Page 76 and 77: G. Lost Foam Foundry-1 Plant Profil
Page 78 and 79: work yielded a 0.85% reduction in s
Page 80 and 81: Stack Melter Like many plants melti
Page 82 and 83: tools. Like many of the other facil
Page 84 and 85: will require that the facility have
Page 86 and 87: 1. Implemented R&D and Best Practic
Page 88 and 89: V-6 blocks, the gating system was c
Page 90 and 91: During their site visit, the team f
Page 92 and 93:
J. Aluminum Casting Facility-2 Plan
Page 94 and 95:
promoting a product line for the fa
Page 96 and 97:
Another alternative for the facilit
Page 98 and 99:
K. Copper Foundry-1 Plant Profile C
Page 100 and 101:
The facility also stays abreast of
Page 102 and 103:
Electric Arc Furnace (EAF) - A stee
Page 104 and 105:
Sprue - Metal that fills the conica
Page 106 and 107:
23 Stratecast, Inc. AFS Metalcastin
Page 108:
99 Ibid. pg. 335. 100 http://www.go
show all

Implementation of Metal Casting Best Practices - EERE - U.S. ...

Create successful ePaper yourself

Delete template?

Save as template?