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

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Treating Sand Iron Foundry-1 reclaims its green sand after the casting is shaken out. The used sand is returned to the sand muller, where additional clay, seacoal, water, and other additives are automatically added to the muller. Once this mulling occurs, the sand is returned to make additional molds. As of now, the used sand that is being returned to the muller is quite hot with temperatures ranging from 140-170ºF. This excessively high temperature leads to poor sand mulling and can also cause sand defects in the castings. Sand in excess of 135ºF in the mold creates extremely high humidity conditions in the mold cavity, and can thus cause degradation of the core and cause serious casting issues that will result in high scrap rates. The assessment team recommended that Iron Foundry-1 consider implementing a system to cool the sand prior to its entering the muller. There are a variety of technologies that are available for this, including water-based systems, fluidized beds, and vacuum cooling systems. These systems generally utilize the cooling effect associated with the evaporation of water. The assessment team recommended that the vacuum cooling system be seriously explored because it removes the heat efficiently and has the least amount of environmental concerns. The vacuum sand cooling system relies on the vacuum-induced evaporation of water rather than air-flow-induced evaporation. Thus, a minimal amount of water-laden air needs to be handled in a dust collection system. These sand cooling systems are a large capital investment, yet they will reduce the scrap rate and will improve the overall productivity. The assessment team recommended that Foundry- 1 perform a thorough cost analysis to determine the payback that can be achieved by implementing one of these systems. Compressed Air There were minimal air leaks observed in the foundry. However, the assessment team noted substantial over use of air at the blow-offs, which are used to remove loose sand from either the sand molds or the molding equipment. The assessment team suggested that Iron Foundry-1 reevaluate the amount of air needed at the blow-offs and adjust/control the air accordingly to implement an easy cost control measure. For example, the blow-offs at one molding machine consisted of 6 to 8 nozzles that appeared to be ¼ inch in diameter. Estimating that a ¼ inchdiameter leak will cost about $1.00/hour, the cost on this line alone for six nozzles is about $6.00/operating hour or $300 per week, assuming 5 days a week, 10 hours per day. Summing this for other machines indicates a significantly large cost. There was also a sizable amount of air being used on the horizontal molding machine tail pulley. Based on a full work year, becasue of the need to maintain pressure for 24hrs a day (i.e., 8,760 hours), and $0.05/kWh electricity cost, leaks or excessive air use costs are as follows: Orifice (diameter) Cost per Year 1/16 inch $523 1/8 inch $2,095 1/4 inch $8,382 60
Cupola Modeling The ITP Metal Casting and the Sensors and Automation programs funded a multi-year project to develop a computer model of the cupola operation to optimize this process for maximum energy efficiency. The project was carried further by S. Katz and Associates, Inc. with the help of a grant from the ITP I&I initiative. The computer model integrates charge metal process variables to predict furnace output based on given inputs. It contains improved algorithms describing SiC performance and has a user-friendly graphic interface. It can help iron foundries optimize operations and reduce energy consumption and greenhouse gas emissions. The assessment team learned on the visit that Iron Foundry-1 had a beta version of the Cupola Model developed with funding from ITP, but never used it. The foundry had used the model owned by a cupola design/engineering firm when designing its current cupola. The assessment team recommended that Iron Foundry-1 use the Cupola Model software to analyze its cupola operations and optimize the system. 3. Conclusion Iron Foundry-1 is a clean, well-run, and technologically current operation. The cupola production of both gray and ductile iron enables them to be a “one-stop” shop for their customers. One major problem observed by the assessment team was returning the sand to the muller operation at high temperature. Addressing this issue will reduce scrap, improve productivity, and save energy at Iron Foundry-1. The foundry also has the opportunity to achieve some energy savings with minimal investment by optimizing its compressed air system and reducing the air usage. Other than these two issues, the facility was found to be operating efficienctly. The recuperative hot blast for the cupola operation is a significant energy saver because it offsets the use of natural gas. Traditionally, the recuperative systems in cupolas are natural gas fired, whereas this system uses the hot off-gas from the cupola as its energy source. 61
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Implementation of Metal Casting Bes
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Executive Summary Since 1995 the U.
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summarized comments regarding the t
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• Metal casters must investigate
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F. Iron Foundry-2..................
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As part of this project, an assessm
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1.3 Report Organization This report
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energy needs, primarily to the larg
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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 42 and 43: 7.8 Installing Energy-Efficient Lig
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 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
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