IfG - Institut für Gießereitechnik (Institute for Foundry Technology) -1- Energy efficiency and recycling in foundries – EffSAFound - a SA–German project Horst Wolff, Head of Department of Manufacturing Engineering and Environmental Control Institut für Gießereitechnik IfG gGmbH (Institute for Foundry Technology - The Institute of the German Foundry Industry) Shareholder: Association of the German Foundry Industry - BDG – Managing director of IfG and BDG: Gotthard Wolf April 2011
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- 1 -IfG - Institut für Gießereitechnik
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Energy efficiency and recycling in foundries –
EffSAFound - a SA–German project
Horst Wolff, Head of Department of Manufacturing Engineering and Environmental Control
Institut für Gießereitechnik IfG gGmbH
(Institute for Foundry Technology - The Institute of the German Foundry Industry)
Shareholder: Association of the German Foundry Industry -BDG – Managing director of IfG and BDG: Gotthard Wolf
April 2011
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applied Research and Development for German foundry industry on materials and process technology
consulting for foundries, foundry suppliers industry, foundry product users
services(chemical and metallurgical analyses, materials testing, damage analysis and damage expertises)
laboratory for industrial safety and environmental control
IfG - working fields
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Employes and Turnover
IfG gGmbH IfG-Service GmbH
Employes 42 16
Turnover –consulting/services [T €]
1,710 1,629
Turnover –research grants [T €]
1,430
Others, IfG-Service [T €] 310
Sum [T €] 3,450 1,629
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Melting and Pouring in IfG
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IfG Training
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EffSAFound – a project financed by the German Federal Ministry of Education and Research in its program CLIENT
Partners:IfG, in cooperation with> MCTS-UJ> SAIF > NFTN> ESKOM
Main objective:to improve the state of the art in S. A. foundries regarding > energy efficiency (reduction of CO2 emissions)> recycling (material efficiency)
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The three spheres of sustainabilty
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Material efficiency
Energy efficiency BAT Energy Efficiency, June 2008
European Standards
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Energy Costs
Iron foundry
Melting55%
Building8%
Air cleaning9%
Fettling8%
Moulding9%
Ladle heating8%
Annealing 3%
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GW
h/a
0
20
40
60
80
1 2 3 4 5
Melting Core making, moulding Air cleaning Compressed air Buildings
%
Energy in Iron Foundries
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Measures for improving energy efficiencyin foundries – possible objectives in EffSAFound
Reduction of amount of metal and melt per casting
Optimization of casting design, e. g. thinner walls Optimization of pouring system and feeders
Minimization of energy consumption in melting and pouring shop
Old or new types of furnaces; melting control Laddle heating System melting furnace - pouring station
Waste heat usage
Minimization of energy consumtion in other foundry shops
Optimization of waste air collection, e. g. avoiding of quartz dust exposure
Non foundry technology specific measures, e. g. compressed air system
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Induction melting: Electricity consumption control system –
example: iron foundry-24 hours
Just in time melting
Cutting the peaks
= minus 5 - 23 % energy costs
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Heating of laddles
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System melting furnace - pouring station
Pouring furnace: more constant temperature
Additional energy consumption: 20 – 30 kWh/t
Temperature of the melt = Pouring temperatur plus 50 - 70 K
Temperature of the melt = Pouring temperatur plus 20 K
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Waste heat and latent heat storage
A phase change material (PCM), e. g. sodium acetate, is a substance with a high heat of fusion which, melting and solidifying at a certain temperature, is capable of storing and releasing large amounts of energy
Heat is absorbed or released when the material changes from solid to liquid and vice versa; thus, PCMs are classified as latent heat storage (LHS) units.
90°C >> 40°C = 2.3 MW/h;
Temperatur loss per day = <0.5%
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ORC (Organic-Rankine-Cycle) process
The Organic Rankine Cycle (ORC) is a thermodynamic process similar to a conventional steam cycle but using a different media to drive the turbine. ORC systems use high molecular organic fluids instead of water.
ORC modules represent an efficient and reliable way to generate electrical power with relatively low temperatures. Since more than a decade such systems operate safely in many places worldwide in a range form a few kW up to 2 MW.
ORC module pre-assembled and ready for delivery
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Measures for improving energy efficiencyin foundries – possible objectives in EffSAFound
Reduction of amount of metal and melt per casting
Optimization of casting design, e. g. thinner walls Optimization of pouring system and feeders
Minimization of energy consumption in melting and pouring shop
Old or new types of furnaces; melting control Laddle heating System melting furnace - pouring station
Waste heat usage
Minimization of energy consumtion in other foundry shops
Optimization of waste air collection, e. g. minimizing the emission of quartz dust, hazardous substances or smell
Non foundry technology specific measures, e. g. compressed air system
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Quartz dust exposure in foundries
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Good Practice Guide on Workers Health Protection throughthe Good Handling and Use of Crystalline Silica and
Products containing it
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Quartz dust exposure in foundriesGood Practice Guide … task sheet 2.2.10
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0,000
0,050
0,100
0,150
0,200
0,250
Sum
me
BTX
[%]
sum
of B
TX [%
]
Coldbox-Biosystem
Coldbox-Klassisches
System
Coldbox-Silikatsystem
Coldbox-Lösungsmittelfrei
Fe-Bindersystem / Fe-binder system
Emission reduced cold box systems –BTX and smell
0,000
2,000
4,000
6,000
8,000
10,000
12,000
Sum
me
Hau
ptge
ruch
strä
ger
[%]
Coldbox-Biosystem
Coldbox-Klassisches
System
Coldbox-Silikatsystem
Coldbox-Lösungsmittelfrei
Fe-Bindersystem / Fe-binder system
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