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Metal Casting Technologies : December 2006
METAL Casting Technologies December 2006 2.1 DATA COLLECTION Energy consumption and process details were collected through a questionnaire from various foundries. This study has been limited to fuel usage in the melting Department and electrical energy consumption in the various departments during the period 2002 -2004. These figures, when compared, given a trend of energy consumption. Energy consumption in different forms should be expressed in a common unit to facilitate easy comparison. The collection of data needs metering facilities for energy used in different sections/equipment. A fair approximation of energy consumption in different processes/ equipment can be made with the help of standard data. 3. EXPERIMENTAL RESULTS The details of the process parameters have been collected from the various sections of the foundries that were surveyed. The consumption of various forms of energy such as electrical, fuel, coal in the above foundries has been tabulated below. Table 2. Energy survey details Table 2 Energy survey details Description Foundry I Foundry II Foundry III Foundry IV Castings Grey CI,SG CI Grey CI Grey CI Grey CI Installed Capacity 10800 Tons/annum 7200 Tons/annum 840 Tons/annum 4800 Tons/annum Actual Production 9000 Tons/annum 6600 Tons/annum 780 Tons/annum 2700 Tons/annum Rejection of products 5% 6% 10% 8% Electrical energy consumption / month 528,500 kWh 100,000 kWh 18,000 KWh 105,000 kWh Transformer 3315 KVA 1000KVA 400 KVA 1450 KVA Motors 595 kW 96 kW 87 kW 228 kW Compressor 242 kW 41 kW 12kW 44 kW Pump 140 kW 38 kW 17.5 kW 33 kW Induction furnace 640 KWH/Ton ----- ----- 690 KWH/Ton Lighting 39 kW 8kW 5kW 14 kW Furnace oil 200 Lt./ton 220 Lt./ton ----- 200 Lt./ton Cupola -- coal ---- 140 Kg/ton 150 Kg/ton ----- Furnace used Induction, rotary Induction rotary, Cupola Cupola Induction, Rotary Melt/day 30 tons 10 tons 3 tons 28 tons Rejection of casting 5% 6% 10% 8% 39