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Green Green , It’s Green They Say, on the Far Side of the Hill……… Folk Song

Green Green , It’s Green They Say, on the Far Side of the Hill……… Folk Song. UNIVERSITY OF JOHANNESBURG COLLOCUIUM 2011. THE SOUTH AFRICAN FOUNDRY INDUSTRY NUMBER OF FOUNDRIES * Includes 4 Investment Casting Foundries In addition there are 13 Art Foundries and 9 Spin Casters

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Green Green , It’s Green They Say, on the Far Side of the Hill……… Folk Song

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  1. Green Green, It’s Green They Say, on the Far Side of the Hill………Folk Song UNIVERSITY OF JOHANNESBURG COLLOCUIUM 2011

  2. THE SOUTH AFRICAN FOUNDRY INDUSTRY • NUMBER OF FOUNDRIES * Includes 4 Investment Casting Foundries In addition there are 13 Art Foundries and 9 Spin Casters cf Germany = 900 USA = 2000 China = 2600

  3. 2. ESTIMATE ANNUAL OUTPUT BY METAL TYPE cf Germany 2.7m Tons USA 11.0m Tons China 39.0m Tons

  4. 4. PROCESS TYPES

  5. 3.1 3. GEOGRAPHICAL LOCATION

  6. 5. Foundry type

  7. 6.1 6. AUTOMOTIVE CASTINGS (Est. Production) 6.2

  8. 7.1 7. EMPLOYMENT (Automotive Foundries) 7.2 Automotive Foundries produce 52 percent of the output with 24 percent of the total staff employed in the industry.

  9. 8. FOUNDRY PRODUCING AUTOMOTIVE CASTINGS • 8 Automotive Iron Foundries generate 48 percent of the total Ferrous tonnage produced • 16 Non Ferrous Foundries produce 70 percent of the total.

  10. GREEN TECHNOLOGY • DEFINITION: Technology that when properly implemented, allows an organisation to meet it’s present needs without compromising it’s future needs. • Green Technology pervades every aspect of our lives • Energy reduction is leading the way towards a greener future • 90 Percent of manufactured goods / products contain cast components

  11. ENERGY SAVING OPPUTUNITIES 1. SCRAP SELECTION AND PREPARATION 2. CHARGING 3. MELTING 4. ALLOYING / REFINING / TREATMENT / SAMPLING 5. HOLDING 6. TAPPING / LADLES 7. TRANSPORTING 8. POURING 9. MAINTENANCE

  12. 1. SCRAP SELECTION AND PREPERATION • Safety • Correct Size • Density • Cleanliness: • Sheared versus Shredded Scrap • Rusted Scrap • Briquetted Swarf • Preheating of Scrap? • Induction Melting Limits the Range of Scrap Used

  13. 2. CHARGING OF SCRAP • Prepare the Charge Sequence • Vibrating Systems • Continuous During the Melt • Pre Heat Charge in the Furnace • Focus on Reducing the Duration of Charging to Maximise the Melting

  14. 3. MELTING THE CHARGE • Mains versus Medium Frequency / cupola • Theoretical Power Versus “Best Practice” • Benefits of Batch Melting • Efficiency (No Holding) 97 Percent • Max Power • Power Density • Melting Rate • Furnace Size • Production Planning • Less Emmision • Improved Control • Improved Homogeneity • Furnace Lids / Covers

  15. Iron Induction Melting Energy Efficiency

  16. Historical Induction Melting Furnace Energy* (Delivered)

  17. Modern Induction Melting Process 3.89 0.08 0.26 0.02 0.29 Losses 1.73 1.81 1.71 1.45 1.16

  18. 4. ALLOYING / REFINING / DE - SLAGGING / SAMPLING • Ferro – Alloy Additions • Sampling – Floor Controls • Sampling – Spectrometer Analysis • Slag Removal – Tools, Efficiency • Slag Wall, Slag Build – Up – Use of Fluxes • Treatment of Metal

  19. 5. HOLDING • Avoid Holding Metal in Batch Furnaces • Melt Cold – Pour Hot

  20. 6. TAPPING / LADLES • Melt Cold – Pour Hot • Refractories • Pre Heating Using Oxy – Fuel to Improve Efficiency • Management

  21. 7. TRANSFER OF MOLTEN IRON • Preparation • Speed and Accuracy of the Operation • Temperature Control • Skimming

  22. 8. POURING • High Power Thermal Plasma Heating • Efficient Heating • Fast • Offers Metallurgical Benefits • Existing Systems = Cold Ladles & Auto Pouring Units Both have Disadvantages • HPTP Offers a Cost Effective Solution • Improved Temperature Control to +- 5 C • Energy Efficiency Improvement of 20%

  23. 9. MAINTENANCE • Refractories: • Replacement Schedule – Push Out • Type of Refractory • Campaign Life • On Going Repairs – Chemical Erosion Leading to Failure • Measurement • Furnace: • Regular Coil Inspection • Water System Quality • Harmonious Controls • Short Main Power Cable Supply

  24. CONCLUSION • There is no “One Size Fits All” Solution • There are no Immediate Technological Innovation in the melting of Iron (No Magic Wand) • Retrofitting Technology is Available • The Approach Recommended is Continuous Improvement in Small Increments • Opportunities for Energy Saving EXITS

  25. ACKNOWLEDGEMENTS • Advanced Melting Technologies “BCS Inc Nov 2005” • Theoretical / Best Practice Energy Use in Metal Casting Operations “JF Suhfo, JT Radia – May 2004” • Improvement in Energy Efficiency of a Melting furnace “Dr DS Padan, Tata Motors Limited” • High Power thermal Plasma Heating in Automotive Casting Units: Tomorrow’s Technology Applied to Today’s Casting “Luis CobosEnal 2010” • Casting Directory 2011 “Crawford Publications” • How to Become a Practical Green Foundry Indsustry? “G Gigante, Thyssen Krupp – Wupaca, WI USA 2010

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