Energy Requirements for Typical Green Sand Foundry sand-binder mixing core forming core curing mold & core assembly mold pouring, cooling shakeout riser.

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Presentation transcript:

Energy Requirements for Typical Green Sand Foundry sand-binder mixing core forming core curing mold & core assembly mold pouring, cooling shakeout riser cutoff & gate removal cleaning, finishing, coating QA / shipping mold making sand renewal metal melting slag, dross removal scrap preparation MJ/kg saleable casting 1.2 MJ/kg 0.7 MJ/kg Melting (MJ/kg) Cupola 6.7 Coke 1.3 Electricity 1.9 Natural Gas 0.1 Oxygen Electric melting Induction Electric Arc Reverb Fuel fired melting Crucible Reverb

Energy Requirements for Typical Green Sand Foundry By Mass Fuel sand-binder mixing core forming core curing mold & core assembly mold pouring, cooling shakeout riser cutoff & gate removal cleaning, finishing, coating QA / shipping mold making sand renewal metal melting slag, dross removal scrap preparation g fossil fuel/kg saleable casting 100 g/kg 60 g/kg Melting (g/kg) Cupola 170 Coke 120 Electricity 50 Natural Gas 5 Oxygen Electric melting Induction Electric Arc Reverb Fuel fired melting Crucible Reverb

Fuel Requirements Using Williams’ conversion –320 g fossil fuel/kWh electricity –40 MJ/kg of nonelectric fuel 1 kilogram casting using EAF requires 900 g fossil fuel 1 kg casting using coke cupola requires 550 g fossil fuel –Disparities caused by efficiency of electricity production, size(?)