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

Thema/Veranstaltung/Datum o.ä. -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

IfG - Institut für Gießereitechnik (Institute for Foundry Technology)
-1-


IfG - working fields

 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

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Employes and Turnover

IfG gGmbH IfG-Service GmbH

Employes 42 16

Turnover – 1,710 1,629
consulting/services [T €]

Turnover – 1,430
research grants [T €]

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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European Standards

Material efficiency

Energy efficiency BAT Energy Efficiency, June 2008

-8-


Energy Costs

Iron foundry
Building
Air cleaning
8%
9%
Fettling
8%

Moulding
9%
Melting
Ladle heating Annealing 55%
8% 3%

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Thema/Veranstaltung/Datum o.ä. - 10 -

Energy in Iron Foundries

80
GWh/a

60
% 40

20

0
1 2 3 4 5

Melting Core making, moulding Air cleaning Compressed air Buildings

- 10 -


Electricity consumption – induction melting - castiron

700
680
660
640
620
kWh/t

600
580
560
540
520
Min - Average - Max
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Electricity/a

Electricity consumption
per Year in the production line
of an iron foundry

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Measures for improving energy efficiency
in 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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 Laddle heating

dust exposure
air system

- 14 -


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

- 15 -


Optimization of pouring system and feeders

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 Laddle heating

dust exposure
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

Temperature of Temperature of
the melt = the melt =
Pouring Pouring
temperatur temperatur
plus 50 - 70 K plus 20 K

Additional
energy
consumption:
20 – 30 kWh/t

Pouring
furnace: more
constant
temperature

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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
90°C >> 40°C = 2.3 MW/h;
classified as latent heat
Temperatur loss per day = <0.5% storage (LHS) units.

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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.
ORC module pre-assembled Since more than a decade such
and ready for delivery systems operate safely in many
places worldwide in a range
form a few kW up to 2 MW.

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 Laddle heating

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

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Quartz dust exposure in foundries

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Good Practice Guide on Workers Health Protection through
the Good Handling and Use of Crystalline Silica and
Products containing it

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Quartz dust exposure in foundries
Good Practice Guide … task sheet 2.2.10

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0,250

0,200

Summe BTX [%]
sum of BTX [%]
Emission reduced 0,150

0,100
cold box systems – 0,050

BTX and smell 0,000
Coldbox- Coldbox- Coldbox- Coldbox-
Biosystem Klassisches Silikatsystem Lösungsmittelfrei
System

Fe-Bindersystem / Fe-binder system

12,000
Hauptgeruchsträg

10,000

8,000
Summe

er [%]

6,000

4,000

2,000

0,000
Coldbox- Coldbox- Coldbox- Coldbox-
Biosystem Klassisches Silikatsystem Lösungsmittelfrei
System

Fe-Bindersystem / Fe-binder system

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Benzol

Emission reduced 7000

6000

nobake systems – 5000

Benzol [mg/m²]
BTX
4000

3000

2000

1000
Toluol
0
1 2

30000 Serien-Furanharz-System Askuran LS-System (Neuentwicklung)

25000

Xylol
20000
Toluol [mg/m³]

15000
800

10000 700

5000
600

500

Xylol [mg/m³]
0
1 400

Serien-Furanharz-System Askuran LS-System (Neuentwicklung) 300

200

100

0
1

Serien-Furanharz-System Askuran LS-System (Neuentwicklung)

- 28 -

EU project Foundry energy efficiency benchmarking

- FOUNDRYBENCH

- 29 -


Foundries and
other partners in
FOUNDRYBENCH

Schmees

- 30 -


FOUNDRYBENCH – Data for benchmarking

Go to FOUNDRYBENCH
Data collection

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Material efficiency: Simulation of core production
Minimization of gas
Core Shooting / Blowing
¬ Incomplete filling for hardening
¬ Inadequate compaction
¬ Optimal Vent/Nozzle
Configuration and Process
Parameters

Gassing / Binder Hardening
¬ Inadequate catalyst contact
¬ Tempering of core box
¬ Optimal Vent/Nozzle
Binder Degradation Configuration and Process
¬ Core Gas related Casting Defects Parameters
¬ Emissions
¬ Optimal Casting Process

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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 Foundry Foundry
and slags sand I sand II
Road construction, pH value >9 >6
limit values in Germany
Conductivity 1,500 2,700
[microS/cm]
Fluoride 9 80
[mg/l]
DOC [mg/l] 30 200

Metals, e.g. 115 120
Chromium
[microg/l]

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Recycling of used sands and
quartz dust
• Cement production, Limit
limit values of the cement industry value
Phenole 40
[mg/kg]
PAH [mg/kg] 20

Metals, e.g. 400
Chromium
[mg/kg]
Nickel 250
[mg/kg]

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•Landfill: road Landfill Landfill Landfill Landfill
construction, Cat. 0 Cat. I Cat. II Cat. III
landfill liner,
limit values in Loss of ignition [%] <3 <3 <5 <10
Germany
pH value 5.5-13 5.5-13 5.5-13 4-13

Fluoride <1 <5 <15 <50
[mg/l]
DOC [mg/l] <50 <50 <80 <100

Metals, e.g. <0,05 <0,3 <1 <7
Chromium [mg/l]
Only landfill liner: < 1* 10-10 < 1* 10-10 < 1* 10-10 < 1* 10-10
Permeability [m/s]

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Recycling of used sands, Limit value
dust and slags
TOC [mg/kg] <6
Recycling of dust and
used sands PAH [mg/kg] 20

•Backfilling in mines, Metals, e.g. 600
Chromium
Limit values (not regarding
salt mines) in Germany [mg/kg]
Nickel [mg/kg] 600

Naphtaline (PAK) 2
[mg/l]
Metals, e.g. 50
Chromium
[mg/l]
Nickel [mg/l] 50

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The EffSAFound project
Time, Duration Action Result

14th, 15th February 2011 Step 1: Kick off meeting with Action plan & time table
discussion of drafts of Workshop programme
Action plan & time table Invitation
Workshop programme  others
Invitation
Further steps
5th – 7th April Workshops Information and invitation to
participate
4th – 12th May Consulting, works visits Definition of objectives and
(MCTS, IfG) measures for improving energy
efficiency and recycling
28th June – 2nd July (GIFA) Discussion and evaluation of Preliminary results
the results of the works visits
July/August Planning of step 2 R & D proposal

October Presentation of EffSAFound- Information on the
Step 1 benchmarking
November 2011 – October 2013 EffSAFound-Step 2 Improving of foundry processes

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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: wolff@ifg-net.de
Farouk Varachia: faroukv@uj.ac.za

Thank you very much for your attention!

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

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