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Metal Casting Technologies : December 2006
METAL Casting Technologies December 2006 38 TECHNICAL FEATURE ABSTRACT he objective of this paper is to identify the areas where energy saving can be made in a cast iron foundry and to investigate the critical energy requirements of various processes involved in it. With the process of civilization and scientific advancements the uses of energy for necessities and for comforts has increased. The demand for energy is also more due to rapid increase in industries due to globalization. In India, due to the limitation of resources for captive generation and identification of useful alternative energy sources, there is always a wide gap between the supply and demand of energy. The details of energy usage in four Iron Foundries in Coimbatore have been studied with a view to ascertain the pattern of energy consumption and compare the same with available standards as set by Confederation of Indian Industry (CII). The fuel energy pattern was studied in the melting department, the electrical energy consumption pattern was done for all the departments of the foundry, and vital conclusions have been drawn Keyword: Energy pattern, Energy consumption, Iron foundry, Regression analysis, Specific Energy consumption, Operational methodology. 1. INTRODUCTION The demand for energy is always due to rapid increases in industries. In India due to the limitation of resources for captive generation and identification of useful alternative energy sources, there is always a wide gap between the supply and demand. Energy audit is a tool in analyzing and controlling demand supply situation. To arrive at the Energy pattern is the main component of the energy audit process. The Energy Pattern is helpful in understanding the way energy is used in an organization and helps to control energy cost by identifying areas where waste can occur and where scope for improvement may be possible. An energy audit and implementation of energy conservation program based on energy pattern will result in energy cost savings. There is a need to look internally to improve margins. Operational efficiency is key to reduce costs. A specific Energy Consumption Study is one such vital area for cost reduction. 2. METHODOLOGY The energy consumption pattern is studied on following steps: i. The existing foundry processes and functions such as pattern design, sand plant, core making, molding, melting, pouring, fettling, shot blasting, heat treatment, secondary machining and inspection were studied. ii. Three separate questionnaires were developed to obtain regarding process parameters, energy consumption and qualitative assessment of resources. iii. The three questionnaires were given to foundries and data regarding all section of foundries were obtained from Engineers/supervisory level personnel. iv. Based on obtained data, the patterns of energy consumption and rejection rate, capacity utilization were developed. v. The developed pattern of energy consumption was compared with CII standard energy norms. vi. Based on the studies and the comparison of the same with standard norms as published by CII, suggestions have been given to respective foundries. Energy consumption in Indian iron foundries By Dr R Gandhinathan and M.Arasu T S.No. Description Energy Consumption 1 Specific power consumption in Induction furnace for cast iron grade 620 KWH/T of Liquid Metal 2 Specific oil consumption in rotary furnace for cast iron grade 135 Lts./T of Liquid Metal 3 Specific coke consumption in cupola for cast iron grade 135 Kg/T of Liquid Metal Table 1 Standard specific energy pattern. The table shows the specific energy consumption for induction furnace, rotary furnace and cupola per ton of liquid metal as published by Confederation of Indian Industry in 2002.