Download - Eff sa found-e&m efficiency-04.2011-4
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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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520540560580600620640660680700
kWh/
t
Min - Average - Max
Electricity consumption – induction melting - castiron
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Electricity consumption per Year in the production lineof an iron foundry
Electricity/a
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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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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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Minimization of wall thickness(e.g. motor block, grey cast iron)
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Optimization of pouring system and feeders
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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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0
1000
2000
3000
4000
5000
6000
7000
Ben
zol [
mg/
m²]
1 2
Benzol
Serien-Furanharz-System Askuran LS-System (Neuentwicklung)
0
5000
10000
15000
20000
25000
30000
Tolu
ol [m
g/m
³]
1
Toluol
Serien-Furanharz-System Askuran LS-System (Neuentwicklung)
0
100
200
300
400
500
600
700
800
Xylo
l [m
g/m
³]
1
Xylol
Serien-Furanharz-System Askuran LS-System (Neuentwicklung)
Emission reduced nobake systems –BTX
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- 29 -EU project Foundry energy efficiency benchmarking
- FOUNDRYBENCH
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Foundries and other partners inFOUNDRYBENCH
Schmees
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FOUNDRYBENCH – Data for benchmarking
FOUNDRYBENCH Data collection
Go to
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Minimization of gas for hardeningCore Shooting / Blowing
¬ Incomplete filling¬ Inadequate compaction¬ Optimal Vent/Nozzle
Configuration and Process Parameters
Gassing / Binder Hardening¬ Inadequate catalyst contact¬ Tempering of core box¬ Optimal Vent/Nozzle
Configuration and Process Parameters
Binder Degradation¬ Core Gas related Casting Defects¬ Emissions¬ Optimal Casting Process
Material efficiency: Simulation of core production
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Reclamation of used sands
Monosystems (e. g. no bake sands;core sands)
Mixed sands (e. g. core sands with green sands)
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Recycling of used sands, dust and slags
Road construction
Cement production
Landfill liner
Backfilling
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Recycling of used sands, dust and slags
Recycling of used sandsand slags
Road construction,limit values in Germany
Foundry sand I
Foundry sand II
pH value >9 >6
Conductivity [microS/cm]
1,500 2,700
Fluoride[mg/l]
9 80
DOC [mg/l] 30 200
Metals, e.g.Chromium[microg/l]
115 120
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Recycling of used sands and quartz dust• Cement production,limit values of the cement industry
Limit value
Phenole [mg/kg]
40
PAH [mg/kg] 20
Metals, e.g.Chromium[mg/kg]
400
Nickel [mg/kg]
250
Recycling of used sands, dust and slags
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•Landfill: road construction, landfill liner, limit values in Germany
Landfill Cat. 0
Landfill Cat. I
Landfill Cat. II
Landfill Cat. III
Loss of ignition [%] <3 <3 <5 <10
pH value 5.5-13 5.5-13 5.5-13 4-13
Fluoride[mg/l]
<1 <5 <15 <50
DOC [mg/l] <50 <50 <80 <100
Metals, e.g.Chromium [mg/l]
<0,05 <0,3 <1 <7
Only landfill liner:Permeability [m/s]
< 1* 10-10 < 1* 10-10 < 1* 10-10 < 1* 10-10
Recycling of used sands, dust and slags
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Recycling of dust and used sands•Backfilling in mines,Limit values (not regarding salt mines) in Germany
Limit value
TOC [mg/kg] < 6
PAH [mg/kg] 20
Metals, e.g. Chromium[mg/kg]
600
Nickel [mg/kg] 600
Naphtaline (PAK) [mg/l]
2
Metals, e.g.Chromium[mg/l]
50
Nickel [mg/l] 50
Recycling of used sands,dust and slags
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Time, Duration Action Result
14th, 15th February 2011 Step 1: Kick off meeting withdiscussion of drafts ofAction plan & time tableWorkshop programme InvitationFurther steps
Action plan & time tableWorkshop programme Invitation others
5th – 7th April Workshops Information and invitation to participate
4th – 12th May Consulting, works visits(MCTS, IfG)
Definition of objectives and measures for improving energy efficiency and recycling
28th June – 2nd July (GIFA) Discussion and evaluation of the results of the works visits
Preliminary results
July/August Planning of step 2 R & D proposal
October Presentation of EffSAFound-Step 1
Information on the benchmarking
November 2011 – October 2013 EffSAFound-Step 2 Improving of foundry processes
The EffSAFound project
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Many thanks to our partners here in S. A. and
thanks to the German Federal Ministry of Education and Research which supports the project EffSAFound and this workshop.
Are you interested in EffSAFound??
Please, use the letter of intent or contact us:
Horst Wolff: [email protected]
Farouk Varachia: [email protected]
Thank you very much for your attention!