by clicking the arrows at the side of the page, or by using the toolbar.
by clicking anywhere on the page.
by dragging the page around when zoomed in.
by clicking anywhere on the page when zoomed in.
web sites or send emails by clicking on hyperlinks.
Email this page to a friend
Search this issue
Index - jump to page or section
Archive - view past issues
button in toolbar for more information.
Metal Casting Technologies : December 2006
METAL Casting Technologies December 2006 TECHNICAL FEATURE ● Referring to articles 3.4, it is observed that Foundry II employs induction furnace and rotary furnace. The specific power consumption of induction furnace is 11% higher and the specific oil consumption of the rotary furnace is 48.5% higher than the CII specified standard norms. ● Referring to articles 3.4, it is observed that Foundry IV employs cupola furnace and rotary furnace. The specific coke consumption of Cupola furnace is 3.51% higher and the specific oil consumption of rotary furnace is 62.96% higher than the CII specified standard norms. ● Referring to articles 3.4, it is observed that Foundry III employ cupola furnace. The specific consumption in cupola furnace is 10% higher in CII specified standard norms in Foundry III. 6. CONCLUSIONS Based on this study the following conclusions have been arrived. i. The Energy Audit conducted on the foundries has become a helpful tool to identify the areas that are abnormally consuming more energy when compared with the CII specified standard norms. The electrical energy consumption of the melting division is generally higher than the standard norms in all the foundries. ii. The following are the suggestions for reducing the energy consumption in melting division. ● The furnace temperature should be measured. ● The alloying elements, inoculants and carburizers have to be added at the right point of time during melting. ● The hold time of the molten metal should be as low as possible. This can be achieved by proper planning of the pouring process. ● The furnaces and ladles should be adequately lined with refractory materials to reduce the heat loss. ● The quality of the raw materials should be maintained at the desired level. iii. The furnace oil consumption is minimum when the melting division is operating with 100 % capacity utilization. Though the capacity utilization of the foundry is mostly decided by external factors (orders received by the foundry, competition, etc.), the following steps can be taken to increase the capacity utilization: ● The company can stagger its melting process until the required numbers of orders accumulate to utilize the full capacity of the furnace, provided it does not loose its customers. ● The capacity of the molding section should match with the furnace melting time. iv. The rejection rate becomes high when employing semiskilled laborers. The following measures are suggested to improve the employee skill. ● The employees have to be trained properly in their respective fields. ● The employees should be motivated to reduce the rejection rate by measures such as suggestion schemes, awards, special training, etc. v. The specific energy consumption of the foundries surveyed is remarkably higher than CII specified norms. The following steps to be taken to reduce the energy consumption: ● The furnace oil pipe line should be free of leakages ● Continuous monitoring of heat input is necessary ● The quality of the furnace oil and raw materials should be maintained always at the desired level ● The employees should follow best practices for the operation of the furnace ● REFERENCES  N.Ketscher, Casting: an energy saving and environmentally production process, Elektrowaerme - Internationale, Vol.55, No.4, pp 119- 124, December 1977.  S.Bhsttacharjee, N.Vasudevan, Energy Efficiency considerations in the Indian foundry Industry, Proceeding of the 31st Intersociety Energy Conversion Engineering Conference, Newyork, USA, Vol.4, pp 2263 -- 2268, 1996.  M.Arasu and Dr.R.Gandhinathan, Energy Conservation in Iron Foundries, Foundry Journal, Vol XIV, No.1, Page 55-58, Jan/Feb 2002.  Wick, Eric.L, Arreaza blanco, Total assessment evaluation of a cupola based to Electric induction furnace replacement, Journal of Energy Engineering, Vol.9, n 5, pp. 33 -- 49, 1998.  Mefffert, william A, Energy assessment in iron foundries, Journal of Energy Engineering, Vol.96, n4, pp. 6-18, 1999.  G.L.Datta, Optimising energy consumption in a foundry, Indian Foundry Journal, Vol.49, No.4, pp.29 --33, April 2003.  M.Arasu and Dr.R.Gandhinathan, Energy Conservation in Iron Foundries, Foundry Journal, Vol XIV, No.1, Page 55-58, Jan/Feb 2002.  G.L.Datta, Energy Management and Audit in Foundries, First Edition, Calcutta, The Indian Institute of Foundrymen, 1999.  Bhaskar Natrajan, An approach to Energy Audit and Management, New Delhi, Ministry of Power, Government of India, New Delhi, 1996.  Bhaskar Natrajan, Energy Audit Report, First Edition, New Delhi, Confederation of Indian Industry (CII), 2002.  M.Arasu and Dr.R.Rudramoorthy, Energy Conservation through Effective Methodology in Iron Foundries, Indian Foundry Journal, Vol.48, No.5, Page 40-43, May 2002.  G.L.Datta, Questionnaire for Foundries, Indian Foundry Journal, Vol.45, No.7. 46-48, July 1999.  M.Arasu, Dr.R.Gandhinathan, Pattern of Energy Consumption in Iron Foundries, Technology Journal, No.1, pp 29-33, July 2001.  K.G.Aswani, Minimising Electrical Energy Expenses, Indian Foundry Journal, Vol.48, No.10, pp.41 -- 44, October 2002.  Fineth.H, Induction and Melting and Holding Furnace in Iron Foundries, Elektrowaerme - Internationale, Vol.29, No.8, pp 459- 461, August 1971.  M.Arasu and Dr.R.Gandhinathan, Energy Efficiency Improvement through Qualitative Assessment Study in Iron Foundries, Foundry Journal, Vol XVI, No.2, Page 53-56, March/April 2004. Dr R Gandhinathan is a Professor in the Department of Production Engineering at PSG College of Technology, Coimbatore -- 641 004. E-mail: firstname.lastname@example.org. His co-author, M Arasu is a Research Scholar in the Department of Engineering at PSG College of Technology E. Email : email@example.com 42