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

Contents
1. Introduction........................................................................................................................... 1
1.1 Background, Objectives, and Scope ................................................................................ 1
1.2 Methodology.................................................................................................................... 2
1.3 Report Organization......................................................................................................... 4
2. Metal Casting Industry Overview ....................................................................................... 5
3. ITP-Industry Partnership Efforts: Energy Efficiency and Best Practices...................... 7
3.1 R&D of Energy-Efficient Technologies .......................................................................... 7
3.2 ITP Best Practices............................................................................................................ 8
1. Process Heating Assessment and Survey Tool.................................................................... 8
2. AirMaster+ ................................................................................................................... 10
3. MotorMaster+ .............................................................................................................. 12
4. Industrial Assessment Centers ...................................................................................... 12
5. Save Energy Now .......................................................................................................... 15
6. Other BestPractices Services........................................................................................ 15
4. Methodology of Assessing Industrial Implementation of ITP Technologies and
BestPractices Tools ..................................................................................................................... 16
5. Overall Assessment Observations ..................................................................................... 18
5.1 Need for a Champion..................................................................................................... 18
5.2 Reluctance in Investigation for Root Cause................................................................... 19
5.3 Need for Business Case Analysis in Decision Making.................................................. 20
5.4 Lack of Awareness of Free ITP Tools and Services...................................................... 21
6. Solutions to Lack of R&D Implementation...................................................................... 23
6.1 Offering Incentives Program to Employees................................................................... 23
6.2 Tracking Impact of R&D Implementation..................................................................... 24
6.3 Providing Explicit Case Studies on ITP Recommendations.......................................... 25
6.4 Increasing Outreach on BestPractices Tools and Services ............................................ 26
6.5 Evaluating the Business Case for Implementation ........................................................ 26
7. Common Energy-Saving Solutions.................................................................................... 28
7.1 Optimizing Melting and Heat Treating Operations ....................................................... 28
7.2 Covering the Furnace and Maintaining Refractories..................................................... 28
7.3 Examine Advanced Retrofitting Technologies.............................................................. 29
7.4 Installing Radiant Panels in Crucible Furnaces ............................................................. 30
7.5 Shifting to Stack Melters ............................................................................................... 30
7.6 Implementing an Energy Management Program ........................................................... 31
7.7 Eliminating Leaks in Compressed Air Systems............................................................. 31
7.8 Installing Energy-Efficient Lighting.............................................................................. 32
7.9 Transitioning to Cogged Belts ....................................................................................... 32
7.10 Scheduling Work during Non-Peak Power Rate Periods .............................................. 32
8. Conclusion ........................................................................................................................... 34
Appendix A: Plant Assessment Case Studies ........................................................................... 36
A. Die Casting Plant-1........................................................................................................ 36
B. Die Casting Plant-2........................................................................................................ 42
C. Steel Foundry-1.............................................................................................................. 46
D. Steel Foundry-2.............................................................................................................. 52
E. Iron Foundry-1............................................................................................................... 57