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Metal Casting Technologies : December 2007
METAL Casting Technologies December 2007 57 70% are possible, again, with very significant savings. One can only assume we will see more requirements for these systems as economic forces put pressure on energy and green house gas reductions. OXY FUEL With an oxy fuel burner, we do not have to heat up the 78% of the incoming air, that is, the nitrogen. Consequently efficiencies are greater. Pipes, ducts, exhaust and bag house are all proportionately smaller. In considering this option from a global green house gas perspective, the power and emissions used in the generation of the oxygen have to be considered. UTILISATION This is not something the furnace designer can control but it needs to be raised . Add poor utilization to all the previous issues and we have a further compounding effect on energy wastage and CO2 emissions. KEY PERFORMANCE INDICATORS For an existing installation it is possible to know how well you are doing and how much room there is for improvement. The first step is to be able to measure. If you do not know what is being produced and consumed then there is little chance of managing performance. Install electricity and gas flow meters on large items of equipment. The second is to analyse performance against best practice The third is to implement strategies to bring poor performances under control The last is to permanently monitor to ensure they stay under control. Typical Key Performance Indicators (KPI) could be graphs trending: ■ Tons produced per month ■ Resources usage per month (electricity, gas, water) ■ Resources usage per ton product (electricity, gas, water) ■ Stack emissions CO2 and NOx CONCLUSION We are already contributing to the consumption of resources and the emissions. We will probably be forced to pay increasing attention to this issue due to moral, financial and legislative pressures. Any new installation should pay careful attention to the matters raised and opportunities to improve on existing plant should be taken proactively. References  Reducing the energy required to produce aluminium, Materials Australia Jan/Feb 2007, 36  The State of Victoria, Department of Primary Industries (April 2004) How many trees do you need to absorb your greenhouse gas emissions?  State government of Victoria 2002, Energy and Greenhouse Management Toolkit, Module 3, Calculating Energy Use and Greenhouse Emissions  State government of Victoria 2002, Energy and Greenhouse Management Toolkit, Green Power Business Guide  Broadbent, Kenneth, C.Eng., M.I.Mech.E (2000), Furnace Efficiency: A User's Guide  Sävenäs, M & Sjödén O, (ABB), Electromagnetics Causing a stir, Aluminium Today, June 2001  Peel, A (EMP Technologies), Alchalabi, R & Meng, F (Chinook Sciences LLC), Furnace Operation Optimisation with EMP System, Alcastek 2002, Aluminium Cast House Technology Conference, Mumbai, India, 206-224  de Groot, J & Migchielsen, J (Thermcon Ovens BV), Retrofitting Melting and Holding Furnaces, Alcastek 2002, Aluminium Cast House Technology Conference, Mumbai, India, 167-181 This paper has been provided by the authors from Furnace Engineering Pty Ltd, 50 Howleys Road, Notting Hill, VIC, 3168, Australia and Thermcon Ovens B.V., De Chamotte 4, 4191 GT, PO Box 97, 4190, CB Geldermalsen, The Netherlands