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BRICS FOUNDRY FORUM 2012 HOSTED BY
CHINA FOUNDRY ASSOCIATION PRACTICAL APPLICATION OF IMPROVING
ENERGY EFFICIENCY IN FOUNDRIES PRESENTED BY: John T Davies
CEO – South African Institute of Foundrymen
THE SOUTH AFRICAN FOUNDRY INDUSTRY
1. NUMBER OF FOUNDRIES
* Includes 4 Investment Casting Foundries
In addition there are 13 Art Foundries and 9 Spin Casters
cf Germany = 900
USA = 2000
China = 2600
METAL TYPE 2003 2007 2011 %Change 2011/2007
Ferrous 110 110 101* 8
Non Ferrous 103 101 80 21
TOTAL 213 211 181 14
DEFINITION
• “Demand Side” refers to the demand for, or consumption of, electricity.
• “Demand Side Management” refers to interventions to reduce energy consumption
• “Energy Efficiency” refers to the effective use of energy to produce a given output (in a production environment)
• technology is one that which produces the same service or output with less energy input.
• “Green Technology” means
• Technology that when properly implemented allows an organisation to meet its present needs without compromising its future needs.
4 4
Per Capita Electricity Consumption for Countries with similar GDP per capita (± 20%) relative to South Africa*
The Case for Energy Efficiency South Africa vs. the Rest of the World
Gabon(1,128 kWh pa)
Russian Federation(6,425 kWh pa)
Venezuela (Bolivarian Republic of)(3,770 kWh pa)
Malaysia(3,196 kWh pa)
South Africa
(4,818 kWh pa)Mauritius
(1,775 kWh pa)
Turkey(2,122 kWh pa)
Saint Lucia(1,879 kWh pa)
Uruguay(2,408 kWh pa)
Panama(1,807 kWh pa)
Argentina(2,714 kWh pa)
Costa Rica(1,876 kWh pa) Romania
(2,548 kWh pa)Grenada
(1,963 kWh pa)
Brazil(2,340 kWh pa)
0.80
0.85
0.90
0.95
1.00
1.05
1.10
1.15
1.20
- 0.20 0.40 0.60 0.80 1.00 1.20 1.40 1.60
Electricity consumption per capita x South Africa Electricity consumption per capita
GD
P p
er
cap
ita x
So
uth
Afr
ica G
DP
per
cap
ita
Source: UN (United Nations). 2007d. The 2004 Energy Statistics Yearbook. Department of Economic and Social Affairs, Statistics Division. New York.
Compared to other countries with a similar per capita GDP (15% variance),
SA is more electricity intensive by factor of 35-
65%
*Situation as in 2004, beneficiation policy and co-generation will alter the above picture
Together we have the power to save 5
Together we have the power to save 6
Benchmarks Programmes Offer
Lighting & HVAC Up to 5.2m/MW
Solar water heating (SWH) Up to 6.3m/MW
Heat pumps Up to 5.2m/MW
Demand Response Up to 3.5m/MW
Compressed Air Up to 4.4m/MW
Process Optimisation Up to 5.2m/MW
Shower Heads Up to 2.8m/MW
Together we have the power to save 7
ESCO Implementation Model
DSM Agreement
Maintenance or Performance agreement
New Engineering Contract
ESCo • Audit
• Proposal • Installation
Eskom DSM • Evaluation • Financier
Customer • Sustainability
ESCo
Heat Treatment 6%
Melting 55%
Post Casting 7%
Core Making 8%
Other 12%
Mold Making 12%
ENERGY SAVING OPPORTUNITIES
1. SCRAP SELECTION AND PREPARATION
2. CHARGING
3. MELTING
4. ALLOYING / REFINING / TREATMENT / SAMPLING
5. HOLDING
6. TAPPING / LADLES
7. TRANSPORTING METAL
8. POURING
9. MAINTENANCE OF PLANT AND EQUIPMENT
1. SCRAP SELECTION AND PREPARATION
• Safety
• Correct Size
• Density
• Cleanliness:
Sheared versus shredded scrap
Rusted scrap
Briquetted swarf
• Preheating of scrap?
• Induction melting Limits the range of scrap used
2. CHARGING OF SCRAP
• Prepare the Charge Sequence
• Vibrating Systems
• Continuous Charging During the Melt
• Pre Heat the Charge in the Furnace
• Focus on Reducing the Duration of Charging to Maximise the Melting Process
3. MELTING THE CHARGE
• Mains versus medium Frequency / cupola
• Theoretical Power Versus “Best Practice”
• Benefits of Batch Melting
• Efficiency (No Holding) 97 Percent
• Max Power
• Power Density
• Melting Rate
• Furnace Size
• Production Planning
• Less Emmision
• Improved Control
• Improved Homogeneity
• Furnace Lids / Covers
• Slag and Dross
Best Tactic Best
Theoretical Industry % Practice % Practice
Selected Processes Minimum Average Difference Minimum Difference Minimum
Iron Induction Melting 351.5 796.3 56% 538.1 35% 1,689.50
Iron Cupola Melting 351.5 1,413.60 75% 1,002.50 65% 1,124.50
Aluminum Reverberatory 288.7 1,399.80 79% 510.5 43% 523.2
Melt Furnaces
Comparison of Practical Minimum, Theoretical Minimum and Best Practice Minimums for
Selected Processes
Estimated Iron Induction Melting Energy Usage
Per Ton Melt
Gross Melt Tacit Tacit Tacit
Item KWh/Ton Loss KWh/Ton KWh/Ton 10 Btu / Ton 10 Btu / Ton 10 Btu / Ton**
Heel Melting Calculated 800 1.5% 812 2550 2.77 8.71 14.52
Heel Melting and Holding Estimated 954 1.5% 969 3041 3.31 10.39 17.31
Modern Batch Melter Caclulated 500 1.5% 508 1594 1.73 5.44 9.07
Batch Melter and Holding Estimated 530 1.5% 538% 1690 1.84 5.77 9.62
Includes Hold Power for 8 Hours per day and preheat gas at 74 kWh/ton melt for heel melter
Ship tons consider 60% yuekd
Induction and Cupola Melting Energy Comparison 10' Btu / Ton
Melt Tacit Melt Tacit Ship
Item Energy Energy Energy
Induction Heel Melting 3.31 10.39 17.31
Modern Induction Batch Melting 1.84 5.77 9.62
Low Efficiency Cupola 4.92 5.76 9.6
High Efficiency Cupola 3.25 3.84 6%
0%
10%
20%
30%
40%
50%
60%
70%
80%
1950 - 1960's 1960 - 1970's 1970 - 1980's 1990's
Energy Efficiency
Tacit Energy Efficiency
Iron Induction Melting Energy Efficiency
0
100
200
300
400
500
600
700
800
900
1950 - 1960's 1960 - 1970's 1970 - 1980's 1990's
kWh/ton
Historical Induction Melting Furnace Energy* (Delivered)
4. ALLOYING / REFINING / DE - SLAGGING / SAMPLING
• Ferro – Alloy Additions
• Sampling – Floor Controls
• Sampling – Spectrometer Analysis
• Slag Removal – Tools, Efficiency
• Slag Wall, Slag Build – Up – Use of Fluxes
• Treatment of Metal
5. HOLDING
• Avoid Holding Metal in Batch Furnaces
• Melt Cold – Pour Hot
6. TAPPING / LADLES
• Refractories
• Pre Heating Using Oxy – Fuel to Improve Efficiency
• Management
7. TRANSFER OF MOLTEN IRON
• Preparation
• Speed and Accuracy of the Operation
• Temperature Control
• Skimming
8. POURING
• High Power Thermal Plasma Heating
Efficient Heating
Fast
Offers Metallurgical Benefits
• Existing Systems = Ladles & Auto Pouring Units
Both have Disadvantages
• HPTP Offers a Cost Effective Solution
• Improved Temperature Control to +- 5 C
• Energy Efficiency Improvement of 20%
9. MAINTENANCE
• Refractories:
Replacement Schedule – Push Out
Type of Refractory
Campaign Life
On Going Repairs – Chemical Erosion Leading to Failure
Measurement
• Furnace:
Regular Coil Inspection
Water System Quality
Control of Harmonics
Short Main Power Cable Supply
CONCLUSION
• There is no “One Size Fits All” Solution
• There are no immediate technological innovation in the melting of Iron
(No Magic Wand)
• Retrofitting Technology is Available for many frequency Furnaces
• The Approach Recommended is Continuous Improvement in Small Increments
• Opportunities for Energy Savings EXIST
ACKNOWLEDGEMENTS
• Advanced Melting Technologies “BCS Inc Nov 2005”
• Theoretical / Best Practice Energy Use in Metal Casting Operations “JF Suhfo, JT Radia – May 2004”
• Improvement in Energy Efficiency of a Melting furnace “Dr DS Padan, Tata Motors Limited”
• High Power thermal Plasma Heating in Automotive Casting Units: Tomorrow’s Technology Applied to
Today’s Casting “Luis Cobos Enal 2010”
• Casting Directory 2011 “Crawford Publications”
• How to become a practical Green Foundry Indsustry?
“G Gigante, Thyssen Krupp – Wupaca, WI USA 2010
• ESKOM – Discussion with the Foundry Industry – Stephen Koopman, Energy Manager RSA 2010