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

• Lack of Awareness of Free ITP Tools and Services: The assessment team found that
very few of the participating facilities were aware of the free tools and services offered
by the ITP Technology Delivery subprogram.
Solutions to Lack of R&D Implementation
Several common factors that hinder the implementation of research results and perpetuate the
lack of awareness of free ITP resources are not unique to the metal casting industry. These are
common problems that can be changed thorough education and by incorporating some
fundamental changes in management practices. The assessment team summarizes these solutions
as:
• Using employee incentives;
• Quantifying metrics to measure the exact result or savings realized;
• Provide more clarification on the recommendations made by IAC;
• Increase outreach regarding and training on the tools and services offered by ITP;
• Provide metal casters with the tools needed to develop a business case to support a
project implementation proposal.
Common Energy-Saving Solutions
A number of the energy-reducing solutions the assessment team recommended for all the
facilities visited can be replicated among other metal casting facilities with little or no capital
investment. They will reduce operating costs and thereby improve a facility’s financial bottom
line. They include:
Process Heating
• Optimize melting and heat treating operations; cover the furnace and maintain
refractories; and install radiant panels in crucible furnaces.
• Shift operations to stack melters for their high efficiency and their improved operability
and design.
Facility Maintenance
• Implement an energy management program.
• Eliminate leaks in compressed air systems;.
• Install energy-efficient lighting with better ballasts, high-efficiency bulbs, and occupancy
sensors.
• Use cogged belts rather than the traditional smooth belts to drive components.
• Schedule energy-intensive processes to occur at non-peak load periods.
• Keep molten metal surfaces covered and optimize ladle heating practices.
Conclusion
The barriers to implementing the ITP Metal Casting R&D and BestPractices can be overcome.
With the assistance of the ITP Metal Casting program, AFS, NADCA, and SFSA, the country’s
metal casters can reduce energy consumption and become more productive. Key conclusions
from the project are:
• The industry can use incentives to encourage employees to undertake energy efficiency
projects and not become complacent with a particular level of imperfection.