1. Energy Saving Concepts and Opportunities in Foundry (A case Study)
Mandana S. Saravani

2. Outline
Objectives
Methodology
Results
Conclusions

3. Objectives Energy Efficiency Opportunities (EEOs)
Determine and benchmark the potential energy and cost savings
Provide guidance for plant managers, energy engineers and other personnel involved in the energy assessment process
Renewable Energy ( Solar)

4. Methodology
Based on American Foundry Society, a 15% reduction in energy costs will increase operating profit by an average of 25%
There are opportunities for improvement in all areas of the foundry
Melting
Molding
Ventilation
Compressed Air
Lighting
HVAC

5. Renewable Energy Generation
Methodology
Renewable Energy Generation
Energy Recovery
Energy Efficiency

6. Methodology EEOs Motors Lighting Comp. Air VFDs Heat Recovery
Energy Efficient belts
Synthetic lubricants
Motors
Energy Efficient lighting fixtures
Lighting controllers (motion, daylight)
Lighting
Install air intake in coolest area
Reduce set pressure
Comp. Air
Pump motors
VFDs
Heat generation as by-product
Use to preheat air/water
Heat Recovery
Load management
Shift processes to off-peak hours
Load Shifting
VFD
Maintain leaks in network
Blowers
Setback temperature & optimize setpoint
Replace equipment and heaters
HVAC

7. Energy and cost saving in the visited plants between 2014-2016
Methodology

8. Methodology For this case study
Plant A and Plant B Selected to analysis the opportunity of installing PV to reduce electricity cost
For system design and simulation, a software called SAM is used

9. Methodology Plant A Total Area : 864 𝑚 2
Annual Electricity cost : $296,029
The total Module Area: 510 𝑚 2
Plant B
Total Area : 670 𝑚 2
Annual Electricity cost : $257,682
The total Module Area: 391 𝑚 2

10. Methodology Annual Cost and Energy Saving
Anuual Energy savings indirect electricity = Annual Cost Savings Average Electricty Cost
Assuming the energy Purchase Price : $0.225/kWh
Plant
ACS ($/year)
Annual Energy Saving (kWh/Year)
Implementation Cost ($)
Incentive($)
Simple Payback Period (Year)
Plant A
27,818
604,739
194,500
100,000
3.4
Plant B
23,014
333,541
149,615
2.1

11. Conclusion
Many research and recommendation efforts have been aimed at the reducing the thermal losses focusing on burner system insulation, control system.
Implementation of better energy management techniques may lead to energy saving of 10% to 15% as well as cost reduction.
Implementing the renewable energy especially solar panel will save a significant amount of energy usage and cost.

12. Thank you!