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Metal Casting Technologies : December 2010
18 www.metals.rala.com.au GREEN TECHNICAL FEATURE Materials/Energy (Input/Output) Case 1 Remelt ingots Case 2 Wrought alloys Liquid aluminium (Al), t 489,466 487,236 Magnesium (Mg), t 882 9882 Silicon (Si), t 11,052 2,210 Copper (Cu), t -- 300 Manganese(Mn), t -- 2,322 Chromium (Cr), t -- 200 Flux (Mg Cl2), t -- 2000 Argon (Ar), m3 150,000 500,000 Lubricants, m3 50 1,000 Refractory's, t 100 2,000 Cast iron (moulds), t 265 265 Steel (packaging), t 1,700 -- N.Gas, TJ 200 1,400 Electricity, TJ 117 240 Water, Ml 281 240 General waste, t 100 100 Dross, t 5,000 7,500 Recycled Al (from dross processing) 2,500 3.750 Energy for dross processing, TJ 10.8 16.2 Table 2. Annual material consumption for the two cast house examples. GHG emissions/Embodied Energy and Water Remelt Ingot cast house Wrought alloy cast house GHG emissions due to furnace heating 25.7 179.8 GHG emissions due to other activities 6.6 44.9 GHG emissions due to electricity consumption 70.2 144.0 GHG emissions due to aluminium melt loss 94.3 141.9 GHG emissions due to magnesium consumption 8.3 93.5 GHG emissions due to other materials consumption 16.6 19.1 Total GHG emissions 221.7 623.2 Primary energy consumed within cast house (including electricity), MJ 1269 5056 Primary energy embodied in lost aluminium, MJ 1176 1769 Primary energy embodied in consumed magnesium, MJ 66 744 Other primary energy (embodied in other then Al and Mg materials, dross recycling, etc.), MJ 345 419 Total embodied primary energy, MJ 2856 7988 Water consumed within cast house, kl 0.56 0.48 Total embodied water, kl 12.48 33.53 Table 3. GHG emissions (kg), embedded energy and water consumption per production of 1t of aluminium alloy product due to cast house activities.