Eff sa found-e&m efficiency-04.2011-4

- 1 -IfG - Institut für Gießereitechnik

- 1 -Thema/Veranstaltung/Datum o.ä.

- 1 -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




- 2 -

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




- 3 -

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




- 4 -

Melting and Pouring in IfG




- 5 -

IfG Training




- 6 -

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)




- 7 -

The three spheres of sustainabilty




- 8 -

Material efficiency

Energy efficiency BAT Energy Efficiency, June 2008

European Standards




- 9 -

Energy Costs

Iron foundry

Melting55%

Building8%

Air cleaning9%

Fettling8%

Moulding9%

Ladle heating8%

Annealing 3%




- 10 -

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




- 11 -

520540560580600620640660680700

kWh/

t

Min - Average - Max

Electricity consumption – induction melting - castiron




- 12 -

Electricity consumption per Year in the production lineof an iron foundry

Electricity/a




- 13 -

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




- 14 -






Waste heat usage







- 15 -

Minimization of wall thickness(e.g. motor block, grey cast iron)




- 16 -

Optimization of pouring system and feeders

http://www.magmasoft.de/ms/products_de_optimization/index.php?PHPSESSID=26714b39efdefde2d90f4bfc6aee42e8

http://www.google.de/imgres?imgurl=http://www.saipamalleable.com/images/magma2.jpg&imgrefurl=http://www.saipamalleable.com/Latin/LIndex.aspx%3Fct%3D16&usg=__XeiftCUeNI60kVWrbpheKJWilVI=&h=344&w=394&sz=18&hl=de&start=17&zoom=1&itbs=1&tbnid=f0FzxyMHmS23rM:&tbnh=108&tbnw=124&prev=/images%3Fq%3DMagmasoft%26hl%3Dde%26gbv%3D2%26tbm%3Disch&ei=sw-aTa_GO5DasgaCqoW4BQ

http://www.google.de/imgres?imgurl=http://www.saipamalleable.com/images/magma2.jpg&imgrefurl=http://www.saipamalleable.com/Latin/LIndex.aspx%3Fct%3D16&usg=__XeiftCUeNI60kVWrbpheKJWilVI=&h=344&w=394&sz=18&hl=de&start=17&zoom=1&itbs=1&tbnid=f0FzxyMHmS23rM:&tbnh=108&tbnw=124&prev=/images%3Fq%3DMagmasoft%26hl%3Dde%26gbv%3D2%26tbm%3Disch&ei=sw-aTa_GO5DasgaCqoW4BQ




- 17 -






Waste heat usage







- 18 -

Induction melting: Electricity consumption control system –

example: iron foundry-24 hours

Just in time melting

Cutting the peaks

= minus 5 - 23 % energy costs




- 19 -

Heating of laddles




- 20 -

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




- 21 -

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%




- 22 -

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




- 23 -






Waste heat usage


Optimization of waste air collection, e. g. minimizing the emission of quartz dust, hazardous substances or smell





- 24 -

Quartz dust exposure in foundries




- 25 -

Good Practice Guide on Workers Health Protection throughthe Good Handling and Use of Crystalline Silica and

Products containing it




- 26 -

Quartz dust exposure in foundriesGood Practice Guide … task sheet 2.2.10




- 27 -

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




- 28 -

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


0

100

200

300

400

500

600

700

800

Xylo

l [m

g/m

³]

1

Xylol


Emission reduced nobake systems –BTX




- 29 -EU project Foundry energy efficiency benchmarking

- FOUNDRYBENCH




- 30 -

Foundries and other partners inFOUNDRYBENCH

Schmees




- 31 -

FOUNDRYBENCH – Data for benchmarking

FOUNDRYBENCH Data collection

Go to

Survey_Energy_English.pdf




- 32 -

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




- 33 -

Reclamation of used sands

Monosystems (e. g. no bake sands;core sands)

Mixed sands (e. g. core sands with green sands)




- 34 -

Recycling of used sands, dust and slags

Road construction

Cement production

Landfill liner

Backfilling




- 35 -


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




- 36 -

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





- 37 -

•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





- 38 -

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




- 39 -

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




- 40 -

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!

mailto:[email protected]




Eff sa found-e&m efficiency-04.2011-4

Documents

Transcript of Eff sa found-e&m efficiency-04.2011-4