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CHAPTER 1
INTRODUCTION
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1.1 BACKGROUND OF THE STUDYThe Indian foundry industry is the second largest in the world. There are more than
6,000 foundries in India. Most foundries (nearly 90%) in India fall under the small and
medium scale category and are located in clusters.
The metal casting industry is naturally very energy intensive. Energy consumption
in foundry mainly depends on electricity. The energy efficiency of any metal casting
facility depends largely on the melting processes. Global warming is putting pressure on
policy makers to formulate and adopt energy policies aimed at different sectors of the
economy, industrial energy efficiency plays a central role in this regards.
Foundry consumes huge amount of energy, and yields tons of wastes. Foundry
industry is one of major energy consumption industry and exerts significant effect on
environment. Energy accounting is necessary to determine where and how energy is
being consumed and how efficient is the energy management system. Energy
conservation and emission reduction is related tightly with the survival and development
of the industry, and it is also a key point of sustainable development Foundry consumes
huge amount of energy, and yields tons of wastes.
Foundry uses two main forms of energy: coke and electricity. In a foundry usinginduction furnace for melting, electricity accounts for about 8595% of the total energy
consumption of the unit. Induction furnace is major electricity consuming equipment, it
consumes about 7085% of total electrical energy consumption. If the foundry units are
heat treating the castings then diesel consumption comes out to around 1525% of the
total energy consumption of the unit. In cupola-based units, coke typically accounts for
8590% of the total energy consumption of the unit.
The energy efficiency of foundry largely rides on the efficiency of the melting
process a multi-step operation where the metal is heated, treated, alloyed, and
transported into die or mold cavities to form a casting. The melting process is not only
responsible for the energy consumption and cost-effectiveness of producing the castings
but it is also critical to the control of quality, composition, and the physical and chemical
properties of the final product.
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1.2 COMPANY PROFILE
Soundcasting is a world class manufacturer of Grey Cast Iron and Ductile Iron
Machined Castings. With a built-up manufacturing area of 39,000 Sq. Meter, we have
fully integrated casting and machining operations run in environmentally friendly
foundries and machine shops. Our specialization is in supplying intricate, cored and fully
machined cast components in the weight range of 10-125 kg and in the volume range of
1,000-15,000 quantities per month to OEMs and system manufacturers. The installed
casting capacity is 5000 tons per month, including a capacity of 1800 tons via High
Pressure Moulding Line (DISAFLEX 70) installed in March 2010.
1.2.1 BOARD OF DIRECTORS
S.No Name of the Directors Designation1 Mr. V.N. Deshpande Executive Chairman2 Mr. N.S. Wagh Non-Executive Vice Chairman
3 Mr. U.K. Deshpande Executive Vice Chairman
4 Mr. Anand V. Deshpande Managing Director
5 Mr. Ravindra K. Kalkundri Joint Managing Director
6 Mr. Abhijeet V. Deshpande Joint Managing Director
Table 1.01: Board of Directors
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1 V.N. Deshpande(Executive Chairman and founder Director)
Mr. VN Deshpande, VN, as he is referred by his friends, is also
Chairman of Deshpande Automech Pvt. Ltd. Kolhapur, a company engaged
in manufacture of Engine and bar components. He is BE (Mech) and
PGDBM. He has past work experience in various industrial organizations in
the area of materials management, oversees technical collaboration, planning
and general management. While he has developed the organization through
various roles, he now takes interest in long term strategic planning, expansion
projects and key stake-holder relations.
2 N.S. Wagh(Non-Executive Vice-Chairman and founder Director)
Mr. Wagh is a BE Mech and BE Met and has a vast experience in the
foundry industry. He has headed various areas in the company including
HRD, marketing and operations. Currently he mentors the management team
on a monthly basis and is on certain board appointed committees.
3 U.K. Deshpande(Executive Vice Chairman and founder Director)
Mr. UK Deshpande has a mechanical engineering background and has
extensive experience in the areas of machining, ferrous casting and foundry
project implementation. He is the Chief Technical Officer and a sensi to the
technical team throughout the organization. Mr. UK Deshpande has led the
successful plant installation and commissioning of our recent HPML line.
4 Anand V. Deshpande(Managing Director)
Mr. Anand has a B Tech in Mechanical Engineering from IIT
Powai, MS in Industrial and Systems Engineering from The Ohio State
University and MBA from University of Akron USA. Anand has worked in
the USA for world class aerospace component manufacturer PPC airfoils
and automotive company Mascotech, a leader in forgings. After working in
the areas of product design and manufacturing he took over manufacturing
of the company in 2000.
He is responsible for creating the quality brand that Sound Castings
is known for today. The ISO 9000, QS 9000 and TS 16949 were taken in a
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short period of time and quality systems were strengthened over the decade
to provide PPM levels at customer end. Anand is a hands-on leader and his
primary focus area is Operations and Human Resource Development.
5 Ravindra K. Kalkundri(Joint Managing Director)
Mr. Ravi is a Chartered Accounted and in his previous career has
practised in several organization including EOU companies. He joined the
company full time in 1993. His acute financial acumen and discipline have
helped the company progress in a systematic and planned manner without
getting unduly leveraged. Ravi leads the finance, accounts and IT area within
the company.
6 Abhijeet V. Deshpande(Joint Managing Director)
Mr. Abhijeet is a Metallurgist and has MS in Net Shape
Manufacturing Systems from The Ohio State University. He also has an
MBA from University of Pittsburgh. Abhijeet has worked for Tier 1, world
class Die casting companies such as Ryobi and SPX Corporation in the USA.
He has experience in the area of customer service, product quality/
engineering and operations management. He is a certified Six Sigma Black
Belt. Abhijeet leads the product development and marketing functions in the
company.
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1.2.2 MANUFACTURINGFoundries
Soundcasting have State of the Art Foundries & Machine Shop at Kagal, Tardal and
Shiroli in Kolhapur.
MIDC Kagal KATP Ind Estate Tardal MIDC Shiroli
Plot area -
44,600 sq m.
Plot area101,171 sq
m.
Plot area7,965 sq m.
Built up area
25,000 sq m.
Built up area8,800 sq
m.
Built up area5,000 sq m.
Power
Connection
-7500 KVA
Power Connection -
5435 KVA
Power Connection -1500 KVA
Table 1.02: Foundry Detail
Present Total Capacity is 5000 MT/month
Fully Automated DISA Make High Pressure Moulding Line Foundry
Box size: 1000 mm x 700mm x 325/325 mm. 2.2 MVA, 750 Kg- 4 nos induction melting furnaces from Inductotherm India DISA make fully automated sand plants with 48MT / hour capacity Draft angles within 1 degree and mis-match within 0.5 mm PLC controlled Cold Box Core Shooters from 5 Kg to 100 Kg single piece
core
Cores dried in conveyor type ovens with appropriate temperature controls Automatic Core sand plants of 5MT/ hour to dry and process core sand Capability of casting modelling, gating design and access to simulation Environmental compliance via use of dust collectors, cyclones, scrubbers and
other pollution control equipments
In-mould cooling of 2 hours followed by 2 hours of air-cooling for largecastings
Spinner hanger type shot blasting machines for good shot coverage
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Mechanised conveyor type paint booth for uniform casting painting
Fully mechanized APRA 900 and ARPA 450 Foundry from DISA India
at Tardal
Box Size of ARPA 900 - 800 mm x 650mm x 225/350 mm. Box Size of ARPA 450 - 650 mm x 650mm x 200/275 mm. 3750 KVA , 2000 Kg3 nos induction melting furnaces from Inductotherm
India
Vibratory chargers and magnetic cranes for feeding furnaces Automatic Core sand plants of 3MT/ hour to dry and process core sand PLC controlled Cold Box Core Shooters from 5 Kg to 18 Kg single piece core
and 3 ton/hr. core oven, more are planned
DISA make fully automated sand plants with 40 MT / hour capacity Automated mould handling system with auto punch-out (knockout) system Spinner hanger type shot blasting machines for good shot coverage
Fully mechanized APRA 450 Foundry from DISA India at Kagal
Box Size of line 1 - 650 mm x 650mm x 175/300 mm. Box Size of line 2 - 650 mm x 650mm x 225/250 mm. 550 KVA , 500 Kg 3 nos induction melting Furnaces from Inductotherm
India
DISA make fully automated sand plants with 36 MT / hour capacity
Mechanized APRA 450/ 300 Foundry at Shiroli
Box Size of line 1 - 650 mm x 650mm x 150/325 mm. Box Size of line 2500mm x 500mm x 150/300 mm. 550 KVA , 500 Kg 3 nos induction melting Furnaces from Inductotherm
India
Sand Plant capacity of 24 MT/ hour
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Core Shops: Equipped with Core Sand plants, Cold Box core shooters
and Core drying ovens
Cold Box Core Shooters
(2)- 100 Kg core shooter (1)- 80 Kg horizontal core shooter (1)- 65 Kg core shooter (1)- 30 Kg core shooter (1)- 25 Kg horizontal core shooter (1)- 20 Kg core shooter (5)-18Kg core shooter (2)-15 Kg horizontal core shooter (6)- 5 Kg core shooter
Shot blasting & fettling / painting in-house facilities
Facilities in Machine Shop
Machine-shop space is available in all three locations and cumulative covered area is 8200 sq
mts.
A] Machining Centers
Horizontal Machining Centres14 nos From maximum pallet Size 800x600 mm (Mazak 6800) to minimum pallet Size
450x450 (Makino A 51)
Vertical Machining Centres- 9 Nos Vertical CNC Turning centres- 6Nos Horizontal CNC Turning centres- 2 Nos
B] Special Purpuse Machines (SPM's)- over 75 nos
C] General Purpose machines
Radial Drilling M/cs: RM 62, BVR 3 Milling M/cs: FN2, FN3 Tapping M/cs Vertical Balancing M/c
D]Common Facilities for Foundry & Machine shop
Electrical Power Connection7500 + 1500 + 5435 KVA
Diesel Generator250 KVA- 3 Nos
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1.2.3 QUALITY & TESTINGSoundcasting have a robust quality system certified to TS 16949 and ISO 9000 by
TUV Nord, an independent IATF approved body.
QC in Foundry:
Spectro-lab make spectrometer (2 nos) Tensile testing machine Microscope with image analyser Chemical testing (wet analysis) Hardness testing Casting sectioning and layout marking
Access to nationally certified labs for radiography, Dye-penetrant, and othertests
QC in Machine shops
3-D CNC controlled CMM (700x1000x600mm- Mitutoyo and Brown &Sharpe make),
1-D electronic height gauges- make Trimos and Tesa Optical profile projector Surface testers, various bore dial gauges, air and water leakage testing etc. All critical characteristics (process and product) monitored by run charts/ SPC PDCA cycle effectively used for root cause analysis of non-conformance Mistake proofing, frugal engineering, cross-functional team working and
continuous improvement are core to our manufacturing
Our goal is to surpass customer ppm target
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1.2.4 PRODUCTS
Figure 1.01: Engine Appilcation
Figure 1.02: Gearbox & Transmission
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Figure 1.03: Axle, chassis and Brake Systems
Figure1.04: Pump, Hydraulic Systems
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1.2.5 CUSTOMERS
Figure 1.05: Customers
Table 1.03: Customer Specific
1 Mahindra & MahindraLtd.- Automotive Sector
2 Mahindra & Mahindra Ltd.-Farm Equipment Sector
3 Mahindra Navy StarAutomotives Ltd
4 Ashok Leyland Ltd
5 John Deere Equipment PvtLtd
6 Kirloskar Oil Engines Ltd7 New Holland Tractors 8 Brakes India Ltd.9 ZF India Pvt Ltd. 10 Windals Precision11 Eicher tractors 12 Tafe
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1.2.6 MILESTONES1988:
Established as a foundry making only 50T per month by Mr. VN Deshpande,
UK Deshpande and Mr. NS Wagh.
1993:
Started Induction furnace melting by adding Inductotherm make furnace.
1998:
Merged Deshpande Industries, an independent machine shop with itself and
expanded the machining set-up.
2000-2006 :
Started various new process improvement and six-sigma initiatives, added
several new customers including Ashok Leyland, John Deere, Kirloskar Oil
Engines and Brakes India.
2007-2009:
Added a plant in Kagal MIDC, added several investments in foundry and
machining, added customers such as ZF and Case New Holland. Capacity
increased to 2200 MT per month.
2010:
Added High Pressure Moulding Line. New customers such as TAFE and Tata
Cummins limited were added, in addition to strengthening relations with
existing customers. Capacity added to 4000 MT/month
2011:
Added new machining Centers including those from MAKINO and MAZAK,
Japan.
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1.2.7 CONTACTSOUND CASTINGS PVT. LTD.
E-2, M.I.D.C., Shiroli, Kolhapur 416122
Maharashatra State, India
Phone +91-9623262099
Fax 91-230-2468219
Figure 1.06: Location Map
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1.3 STATEMENT OF THE PROBLEMUntil recently, in most industries energy costs were regarded simply as a cost
of doing business, and little attention was paid to them. The level of interest in efficient
energy use had been moderated by continuing low electricity and fuel prices that
prevailed until 2000.After 2000 due to price of electricity hike its added urgency to the
need to examine the effectiveness of energy use in Soundcasting.
1.4 NEED OF THE STUDYThe need of this study is to explore Grand Challenge or breakthrough
opportunities that might dramatically reduce energy consumptions and Identification to
potentially energy-saving based on the findings.
1.5 SCOPE OF THE STUDYThe scope of the study includes energy consumptions and identification to
potentially energy-saving applications in the metal casting industry in domestic markets.
Although, the report focuses on foundry applications, the energy management programs
discussed in this report are in general applicable to all casting industry and other
industries.
1.6 OBJECTIVES OF THE STUDY Determination of the energy consumption pattern. Helps to control energy cost by identifying areas where waste can occur and
where scope for improvement may be possible.
Finding energy management programs further.
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CHAPTER 2
LITERATURE REVIEW
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2.1 POWER DISTRIBUTION TREE OF FOUNDRYIn figure the main processes of foundry energy consumption is shown so that one
can understand the whole system step by step with power consumptions in different
departments and also the losses
Figure 2.01: Power distribution tree of FoundryThe foundry industry is one of the most energy-intensive industries accounting for
one-eighth of all the energy supplied to industries. Main foundry classes are Gray- and
ductile-iron foundries (Standard Industrial Classification code 3321), malleable-iron
foundries (SIC 3322), and steel foundries (SIC 3325)these represent more than 95 percent
of the total foundry energy consumption in Wisconsin.
The American Foundry mens Society Cast Iron Directory 1995-1996 lists 191
foundries in Wisconsin, of which about 154 fall into the three ferrous iron categories listed
above. Gray- and ductile-iron foundries account for more than half of this total, followed
closely by steel foundries. There are only three malleable-iron foundries listed. Although
many of Wisconsins ferrous foundries are relatively small, some high-volume plants are in
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production. One Wisconsin plant, for example, melts approximately 700 tons of metal per
day, and total daily energy consumption can reach 1000 kWh.
This study was designed to provide information that could be used to help identify
ways to improve process energy efficiency at foundries. To do this we performed an
extensive review of the literature to develop the consistent foundry information resource
presented through this report. This information is designed to provide utilities, government
agencies, and energy-service providers with the data they need to design and deliver
effective energy-saving programs for Wisconsin foundries.
2.2 CURRENT INFORMATION ON PROCESS ENERGYUSE
Among major processes, the melting process consumes the most energy in a foundry,
representing about 50 to 80 percent of the total energy required to produce a casting. Typical
energy-consumption values found in the literature for the three primary melting processes
for Gray iron are shown in Table
Figure 2.02: Energy consumption of melting processes (kWh per ton of casting sold)
These figures depend on casting efficiency. All castings have risers and runners that
are needed to produce a shrinkage-free product. Depending on how the casting is designed,
the quantity of returns can vary between 30 and 95 percent. This material is melted but does
not become a part of the finished casting. Hence, the energy used per ton of finished casting
can vary substantially with the efficiency of the foundry, the intricacy of the mold, and the
ability to reduce the quantity of metal returned.
Although foundry processes may appear to be relatively homogeneous when
compared with processes of other industries, significant variations between plants and
processes exist. The great diversity of thermal operations in a foundryresulting from the
different types of energy used, the working procedures used, production capacity, the nature
of alloys produced, the dimensions of castings heat treated, and the effective castings yield
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makes it difficult to establish an overall ratio of foundry energy consumption per ton of good
casting that would be significant to all foundries.
It has been difficult to develop average, typical, and best practice energy balances
for Wisconsin foundries because of a lack of published information on energy consumption
in specific foundry processes. Literature data tends to focus on the melting process; little or
no data are available on energy consumption in the other foundry processes. The bulk of the
information available is for Gray iron foundries, with limited data for ductile-iron,
malleable-iron, and steel foundries. Most data are for production prior to 1983. Since that
time, some foundries have taken steps to improve efficiency in the areas of yield
improvement, oxygen melting assistance, furnace and ladle insulation, and recovery of heat
previously discharged to atmosphere. As a result, Wisconsin foundries may be operating
more efficiently than indicated by most information sources.
2.3 INFORMATION DATABASE2.3.1 Developing Process Baselines
We collected information on the major melting processes common to
foundries. These data were often from highly detailed studies of foundry practicesand represent comprehensive information on foundry melting process energy
consumption. Energy consumption figures collected for processes other than melting
were less complete. The energy consumption data for melting processes were
obtained from compilations available in the literature.
2.3.2 Cupola Melting ProcessA major problem with comparing the coke consumption in cupolas is that
some of the coke input is used for adjusting the metallurgical composition of the
casting and is not combusted. Also, energy content of coke is variable and rarely
reported in the literature. We used an energy content of 22.72 million BTUs person
to convert coke consumption in cupolas reported in tons to energy units. We assumed
that all of the data reported are for coke consumption in conventional coke cupolas.
Coke less cupolas which use natural gas or oil as their primary fuel a re also
available. These newer types of technology are often used in duplexing operations
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combining coke less gas furnaces with electric induction holding furnaces. Many of
the literature sources do not specifically list the type of cupola or the fuel consumed.
About two-thirds of the data reported for cupola energy consumption are from
Canadian and British studies of cupola energy consumption. The Canadian study
(Warda et al, 1981) presents data from a detailed engineering study of thirty cupolas
conducted by the Canada Centre for Mineral and Energy Technology in the late
1970s. The British study (Energy Technology Support Unit, 1990a) draws on two
main sources of data; a recent questionnaire survey of the British foundry industry
conducted in 1989-90 and information from a British Cast Iron Research Association
study conducted in 1979.
We obtained only two data points for cupola melting energy in ductile-iron
foundries. One was from the British foundry survey (Energy Technology Support
Unit, 1991), and the other was from a Wisconsin foundry taken from a survey of
Wisconsin foundries (Leadon, 1984).We obtained only three data points for cupola
melting energy in malleable iron foundries (Energy Technology Support Unit,
1990a).
2.3.3 Induction Melting ProcessOne difficulty in comparing data for induction furnaces is the issue of
holding. Often medium frequency furnaces are installed as a pair, so that the melting
furnace can also perform the role of holding/pouring of molten iron after completing
each melt. Unlike the cupola and the mains induction furnace, the quoted energy
consumption would therefore include both the melting and holding/pouring
processes. Holding of molten iron following the mains and cupola melting processes
is most often accomplished by a channel induction furnace and energy consumption
data are often reported separately. According to data collected as part of the British
Energy Efficiency Office survey of coreless induction melting furnaces, (Energy
Technology Support Unit,1991), average energy consumption by mains frequency
induction furnaces was751 kWh/metric ton (681 kWh/US ton) of metal melted while
energy consumption in medium frequency installations was 818 kWh/metric ton
(742kWh/US ton). For reference, the theoretical electrical energy needed to melt cast-
iron and raise its temperature to 1450 C (2650 F) is about 419 kWh/metric ton(380
kWh/US ton). Considering coil and heat losses at about 20 to 25 percent, the
minimum energy consumption for highly efficient induction furnaces would-be about
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459 kWh/metric ton (416 kWh/US ton).More than half the data collected on induction
melting process energy consumption for this study comes from the British Energy
Efficiency Office survey. Data were obtained for only Gray-iron foundries and steel-
foundries. Figures for yield were not available; nor were overall energy intensity
figures for total foundry operations using induction melting processes. The majority
of the data for steel foundries were taken from the International Cast Metals Journal
(American Foundry mens Society, 1980), which gave only ranges of expected
energy intensities for steel induction melting processes rather than empirical data.
The one real data point (fora Wisconsin steel foundry) taken from the survey of
Wisconsin foundries (Leedom, 1984), is within 95percent of the theoretical minimum
energy intensity.
2.3.4 Duplex Melting ProcessThe most detailed data reported for duplex melting are from Leedom (1984)
fora foundry using a cupola and duplex process in two plants. There are two data
points each for ductile-iron and Gray-iron castings.
2.3.5 Electric-Arc Melting ProcessWe collected data for the arc melting process for Gray iron and steel. Most
of these data points were taken from Leedom (1984). All of the data for Gray ironis
10 to 15 years old. Data for arc melting for steel production contains both recent data
for state-of-the-art operations and older data from the early 1980s.
2.3.6 Induction Holding ProcessEnergy consumption data for induction holding processes was collected on
the basis of energy consumption per unit of metal throughput. Many variables
influence the energy intensity of holding a molten charge including technology,
continuous vs. intermittent operations, length of time required for holding, and
superheating as in a duplex/holding furnace. Information on these other important
variables was not provided in the literature along with the energy consumption
figure. We collected data for three different holding processes: duplex furnace,
channel induction furnace, and crucible furnace. The majority of the data collected
was for Gray iron, although we found two data points for ductile iron. All of the data
are between 10 and 15 years old. A few data points are from a Wisconsin foundry.
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2.4 INTERPRETING PROCESS ENERGY CONSUMPTIONESTIMATES
The figures presented in this report may overestimate energy consumption becausemany estimates were based on pre-1983 data. With the fall of real energy prices, energy
consumption in foundries has not been featured prominently in foundry literature. Since the
early 1970s, some foundries have taken steps to improve energy efficiency. The major
improvements have been in the areas of yield improvement, oxygen melting assistance,
furnace and ladle insulation, and recovery of heat previously discharged to atmosphere. On
the other hand, increases in pollution control apparatus have resulted in increased energy
consumption. Even so, Wisconsin foundries are probably operating more efficiently than
indicated by the outdated energy intensities available in the literature. We estimate that they
are as much as 25 percent more efficient than indicated by the pre-1983 figures. The data
shown for duplex process energy consumption must be viewed with extra caution. The data
were highly aggregated, and thus may not accurately represent actual energy consumption.
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CHAPTER 3
RESEARCH METHODOLOGY
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3.1 PROBLEM RECOGNITIONThis study is focused on determining the practical potential for reducing energy
requirements in the Soundcasting industry by looking at industry best practices, which
are referred to as best practice minimums. Both equipment design efficiencies and
operating procedures related to reduced-energy consumption are discussed in detail. The
highest energy consuming processes within each casting alloy family were investigated
to determine the potential for energy reduction measures.
The theoretical minimum energy requirements are also calculated for the major
energy consuming processes. The theoretical minimum energy requirements are
calculated by ignoring all energy losses and therefore are not achievable in practice. A
baseline of current foundry energy usage was also determined from the best available
information and is referred to as the industry average. The industry average energy
usage was then compared to the best practice to determine the potential for energy
reduction using existing and proven technologies and procedures.
Material and energy losses during process steps represent inefficiencies that waste
energy and increase the costs of melting operations. Modifying the design and/or
operation of any step in the melting process may affect the subsequent steps. It is,
therefore, important to examine the impact of all proposed modifications over the entire
melting process to ensure that energy improvement in one step is not translating to
energy burden in another step.
3.2 RESEARCH APPROACHAn energy management program follows the same principles that apply to
any purposeful undertaking (e.g., to quality and environmental management systems)
principles that Dr. Deming formulated as the four-step cycle, PlanDoCheckAct,
PDCA, shown below.
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.
Figure 3.01: Four key steps
The four stages of the PDSA cycle:
Plan - The change to be tested or implemented.
Do - Carry out the test or change.
Check- Data before and after the change and reflect on what was learned.
Act - Plan the next change cycle or full implementation.
To realize opportunities, foundry management must successfully integrate
organizational and behavioural (cultural) change and new energy use technology. The
energy efficiency effort must have a defined focus, accountability and responsibility.
The points in Figure are generic and given for information only. Their application will
vary with the size and complexity of a foundrys operations and will be determined by
site-specific conditions of a particular energy efficiency improvement program.
3.3 DATA COLLECTION METHODS3.4.3 Primary data
Primary data is the data that is collected for the first time i.e. the data did not
exist before the collection. In this report primary data has been produced by for
example finding energy usage across different utilities in company.
3.4.4 Secondary DataSecondary data consist of data which has been collected in another
context. In this report the data is collected from literature searches were
conducted to obtain available information on energy conservation in the
metal casting industry and from company annual report.
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Literature searches conducted for this study provided many
documents written by the metal casting industry and federal government
agencies. The specific documents referred to for relevant casting energy data
are listed in the reference section of this report. A significant study that
yielded very accurate energy data for a specific number of facilities is the
Energy Use in Select Metal casting Facilities, which was a quantitative
study that performed onsite measurement of energy use. The study gives
energy profiles for a cross section of casting facilities and was used along
with other foundry-specific studies.
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CHAPTER4
DATA PROCESSING AND ANALYSIS
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4.1 FOUNDRY TECHNOLOGIESThere are several types of equipment and technologies that are widely used in the
foundry process. Some of the major ones include:
Melting furnaces Sand mullers Intensive mixers Pneumatic grinders Shell moulding machine Core oven Shell core shooters
Knockout machine Shot blast machine
The major equipments are described below.
4.1.1Major equipment used in foundry units(a) Melting furnaces
Two types of melting furnaces are commonly used in a foundry cupola and induction furnace. While cupola uses coke to melt the metallic charge
materials, an induction furnace uses electrical energy. Although the energy cost
per tonne of molten metal is lower in a cupola, other advantages of induction
furnaces, viz., faster start-up, lower manpower requirement, and lower emissions
have contributed to their increasing popularity among foundry units in Kolhapur
cluster.
(b) Sand mullers
These are used for green sand preparation. Fresh sand is mixed with
bentonite and other additives and mixed in Muller to make green sand. These
usually come in small size of around 300 kg per batch, with typical connected
drive of 10 kW and cycle time come about 710 minutes.
(c) Intensive mixers
Cores are forms that are placed into the mold to create the interior
contours of the casting. They are typically made of clay-free silica sand mixture.
The sand is thoroughly mixed with suitable binders, water, and other ingredients
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in intensive mixers. This equipment basically has two motor drives, used to rotate
the blades and perform mixing. A typical 10 tonne per hour, 500 kg batch-
intensive mixture has a total connected load of around 70 kW.
(d) Shell-moulding machine
This is usually located below the sand mixer. Sand from a hopper falls
into the moulding box and then pneumatically or hydraulically pressed to make
the final mould. High pressure moulding machines can use moulding sand having
lower moisture contents and hence higher mould densities can be achieved. The
castings have better dimensional accuracy and better surface finish.
(e) Knock-out machine
The knock-out machine has grated base, and it has two vibrators one
on either side or a single vibrator.
(f) Shot blasting
There are different types of shot-blasting machines available; the
most common ones in Kolhapur foundry cluster are double door, two shooters
type. It has four drives, two for shooters, one of bucket rotating, and one for dust
collection. Typical 1 tonne per batch shot blast machine has total connected load
of around 25 kW.
4.2 FOUNDRY PROCESS DESCRIPTIONDifferent stages in manufacturing of a casting include the following:
4.2.1 Preparation of moulds and charge materialThis involves preparation of (i) moulding sand, (ii) casting moulds, and (iii)
charge (metals and alloys). Fresh sand is mixed with bentonite and other additives
and processed to prepare green sand, which is the most commonly used moulding
sand in Soundcasting, typical batch size varies between 200500 kg. The green sand
is then used to prepare moulds for the castings. Simultaneously, metal scrap, pig iron,
and other alloys are loaded in the furnace for melting. The ratio between raw
materials depends on final casting properties. A typical cast iron casting has raw
material in following percentage: metal scrap (25%), boring (60%), pig iron (10%),
and others (5%).
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4.2.2 Melting stageThe metal is then melted in either a cupola furnaceconventional or divided
blastor induction furnace. The typical temperature requirement for CI casting is
around 1500C, steel casting is around 1650C, and for aluminium casting 750C.Once the melting is completed, the molten metal is poured into the sand moulds using
a ladle operated either manually, automatically, or semi-automatically, that were
prepared in the first stage and allowed to cool down and harden.
4.2.3 Finishing stageOnce the metal has taken shape of the mould, it is removed, shot blasted, and
cleaned. It also goes through some machining, if required. The final product is tested
using spectrometer and packed for dispatch. Meanwhile, the sand from the mouldsis either disposed or treated in a sand reclamation plant for reuse. Units using sand
reclamation in Soundcasting are generally able to reuse about 80% of the sand. A
more technical illustration of the manufacturing process of a typical foundry unit in
the Soundcasting is presented in Figure.
Figure 4.01: Manufacturing process of a typical foundry unit in Soundcasting
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4.3 TYPES OF FUEL AND USAGE IN MSMES4.3.1Fuel types and quantity used in typical MSME units
Foundry uses two main forms of energy: coke and electricity. In a foundry
using induction furnace for melting, electricity accounts for about 8595% of the total
energy consumption of the unit. Induction furnace is major electricity consuming
equipment, it consumes about 7085% of total electrical energy consumption. If the
foundry units are heat treating the castings then diesel consumption comes out to around
1525% of the total energy consumption of the unit. In cupola-based units, coke
typically accounts for 8590% of the total energy consumption of the unit.
4.3.2Specifications and characteristicsCoke is used in foundries where the melting process is done in a cupola furnace
(conventional or divided blast) and electricity is used in units where melting is done in
an induction furnace. Other processes in a foundry such as sand preparation, machining,
shot blasting, etc., are all operated using electricity, irrespective of whether the foundry
is cupola based or induction based. Metallurgical coke is being used as fuel in cupola
based units in the cluster. The calorific value of the coke varies between 55006500
kcal/kg.
4.3.3Price/Tariff ElectricityThe price of electricity has increased from INR 5.90 per unit to INR 8.50 per unit in
Kolhapur. Figure 7 shows the trend over the last four years. The price shows an
increment of over 15% during this period.
Figure 4.02: Energy price (20092012)
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4.3.4CokeThe price of coke has increased over the last year and is presently about INR 30,000
per tonne.
4.3.5SourcesElectricity to Kolhapur is supplied from the Maharashtra State Electricity
Distribution Company Limited (MSEDCL). MSEDCL supplies electricity to 3.63 lakh
industrial consumers sourcing its power from thermal, hydro, gas, and non-conventional
sources like solar, wind, bagasse, etc. Coke is being supplied from various sources
which include Sesa-Kembla Goa, Gujarat NRE, and also from some suppliers in
Nagpur.
4.4 ENERGY CONSUMPTION PATTERN4.4.1 Utility-wise energy share
The share of energy usage across different utilities in Soundcasting foundry
is given. As shown, the majority of energy is consumed for the melting process
(about 70%). Moulding, core making, and sand preparation are also significant
consumers in the process.
Table 4.01: Utility-wise energy share in Soundcasting
It is observed that melting consumes a major portion of total energy consumed.
4.4.2 Energy consumption in melting furnacesA foundry had two medium frequency induction furnaces. The unit had fair
energy metering and reporting systems. Every melting furnace was connected to an
individual energy meter (average type). Every day the consumption and production
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of each furnace was recorded and monitored. The furnace details are presented in
table
Furnace
#
No of
crucibles
Crucible
Capacity,
kg.
Rated kW Rated
frequency,
Hz
Average
specific
consumption,
kWh/Mt
# 1 2 1000 &
1000
1000 500 674
# 2 3 500,500&
1000
550 100 777
Table 4.02:Furnace details with specific energy consumption
4.4.3 Energy consumption in CompressorsAir compressors were used in the machine shop for pneumatic equipment
and machine tools. While visited the foundry compressor system had found some
issues were presented below in table
Present system of Air compressor system
Location of the compressor was near
by the heat source that shown the
reason of rise in inlet temperature may
reduce power saving.
Measured temperature of inlet air is
about 45C by contact thermometer.
Regular checking of leak were not
taken place that cause pressure drops
that adversely affect the operation of
air-using equipment and tools,
reducing production efficiency.
Table 4.03:Present system of Air compressor system
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4.4.4 Present system of electrical distribution in foundryIt was found during visit that present electrical distribution system was not
proper with respect to timing and capacitor as presented in table
Present system of electrical distribution in
foundry.
No load is being shifted to Night
timing when the electricity is at low
cost.
There are no any capacitors using in
electrical system to maintain or
improve the power factor.
Table 4.04: Present system of electrical distribution
4.5 Energy management planTo start, a few major components must be put in place:
1. Firm commitment of top management2. Clearly defined program objectives
3. Organizational structure and definition of responsibilities
4. Provision of resourcespeople and money
5. Measures and tracking procedures
6. Regular progress review
Table 4.05: Energy management plan
Plan -Predict and prevent troubles beforehand.
Do -Educate and train employees.
-Implement the plans.
Check - Compare the results against the targets.
- When the results fall short, examine the causes.
- Take immediate measures.
- Analyze the process and identify the root causes and develop
Act -Revise the standards.
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4.5.1 Energy Saving Guideline Turn off lights (and other equipment) when not in use. High utility costs often
include paying for energy that is completely wasted.
Replace incandescent light bulbs with ENERGY STAR qualified compactfluorescent lamps (CFLs), wherever appropriate. CFLs cost about 75 percent
less to operate, and last about 10 times longer.
Adjust lighting to your actual needs; use free "daylight" during the day.
Turning off machines when they are not in use can result in enormous energysavings. There is a common misconception that screen savers reduce energy
use by monitors; they do not. Automatic switching to sleep mode or manually
turning monitors off is always the better energy-saving strategy.
To maximize savings with a laptop, put the AC adapter on a power strip thatcan be turned off (or will turn off automatically); the transformer in the AC
adapter draws power continuously, even when the laptop is not plugged into
the adapter.
Fix leaks of water. Small leaks add up to many gallons
Unplug battery chargers when the batteries are fully charged or the chargersare not in use.
Air ingress into the furnace (heat treatment furnace) causes significant lossof energy. All that extra air needs to be heated to maintain the proper furnace
chamber temperature. Air ingress may reduce cold spots and quality
problems as well.
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Figure 4.03: Radiation losses
The radiation losses are serious in melting furnaces (e.g., induction furnaces)where they occur through open lids, open dross removing or slagging doors,
from ladles with no or inadequate covers during heating, and especially
during molten metal transfer.
For thermal losses and conductive heat sinks, it is a question of adequateinsulation and furnace or ladle lining with the right type of refractory
materials. If dense firebrick is used for lining the furnace, it needs to be
installed in adequate thickness to limit the heat conductive losses.
Energy management is an ongoing concern in any foundry. Its success
depends on a team effort starting with a firm commitment from the top executive and
his or her management team. Managements demonstration of unwavering, solid and
visible support filters through the organization to each employee. Everybody will
take heed and will follow the example. Once the decision to manage energy has been
reached, it should be supported by a board-level energy policy, which will regard
energy and the cost of utilities as direct costs on par with other operational costs,
such as labour, raw materials, etc.
A build-up of general awareness about energy issues through
communication, education and training of employees at all relevant levels will
contribute to a cultural change within the organization. Education and training must
be sustained in order to achieve lasting energy efficiency improvements. Sometimes,
even when the opportunities for energy savings are great, they are not utilized.
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The reasons fall into the familiar:
Was not aware of opportunities that exist;
Did not know what to do;
Top management not supportive;
Energy issues not a priority;
No money and/or staff and/or time; and
No defined accountability.
Since the primary business goal is financial savings, managers must
understand the principle of economics and run their department as if it were their
own business. In doing so, improving energy efficiency should get proper attention.
This will require some education. Even if the financial gains from energy efficiency
improvements were to seem modest compared to the value of sales or to the overall
budget, they can contribute considerably to the foundrys net profit.
4.6 ENERGY EFFICIENCYThe energy efficiency of the melting process is calculated by dividing the
amount of theoretical energy needed to melt a metal and raise it to its pouring
temperature by the actual amount of energy consumed in melting, treating, holding
and handling the material.
4.6.1 Energy Savings in Induction Furnaces The heat cycle that is pouring to pouring, recorded about 25-40% of the specified
standard time.
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The power to the furnace was varied very frequently due to empty space in thecrucible, excess charge, and sample analysis delay.
The recorded electrical parameters indicate that about 35-40% of the heat timethe furnace was operated at 70-80% of rated power.
About 80% metal is charged before taking the sample for the analysis. Theremaining 20% of crucible volume is loaded after obtaining the sample analysis.
The first batch sample analysis indicates the short fall of different elements,based on this the additional material is added to achieve the required composition
and quantity.
Furnace # 1 Furnace # 2 Furnace Total
Possible reduction in time (min) 6 8 -
Reduction in energy (kW) 24 23.4 47.4
Operating days per year 330 330 -
Operating hours per day 22 17 -
Energy savings (Lakh
kWh/year)
1.95 1.33 3.88
Annual cost savings (Rs. Lakh) 6.30 4.06 10.36
Investment required (Rs. Lakh) 1 1 2
Payback period (Months) 2 3 2
Table 4.06: Details of Saving
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4.6.2 Energy Savings in the Compressed Air SystemThe relation between inlet temperature and relative air delivery and due to
that power consumption can be analysed and it can be seen that lower inlet
temperature can save more power.
Foundry had found inlet temperature about 45C. So from table it consumes morepower. While extending the air intake from the outside of the building, minimize
excess pressure drop in the suction line by selecting a duct of large diameter with
the smallest number of bends that gave air at 32C temperature.
Locate the compressor away from heat sources such as kilns, dryers and otheritems of equipment that radiate heat.
Inlet Temperature (C) Relative Air Delivery
(%)
Power Saved (%)
10.0 102.0 + 1.4
15.5 100.0 Nil
21.1 98.1 1.3
26.6 96.3 2.5
32.2 94.1 4.0
37.7 92.8 5.0
43.3 91.2 5.8
Table 4.07: Effect of intake air temperature on power consumption
4.6.3 Proposed energy Savings in the Electrical Distribution System Stagger the non-critical load according to the electricity tariff to reduce the
energy bill. The benefits of load staggering are shown in Table 8.
Maintain a high power factor, which will lead to reduced demand, better voltage,high system efficiency as well as rebates from the electricity supplying company.
The power factor can be improved by installing capacitors in the electrical
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system. Table shows the benefits of power factor improvements from the point
of view of costs.
Control the maximum demand by tripping non-critical loads through a demandcontroller. This will avoid the penalty levied when usage is greater than the
sanctioned load.
Balance the system voltage to reduce the distribution losses in the system. Forevery 1% increase in voltage imbalance, the efficiency of the motors decreases
by 1%.
Load to be shifted to night shift (10 PM - 6 AM) 15 kW
Assumed working hours per shift 8 hours
Monthly power consumption (30 days/month) 3000 kWh
Electrical cost for night shift operations
( assuming Rs 3.5/kWh during 10 PM - 6 AM)
Rs 1,0500
Electrical cost for general shift operations (assuming Rs.
5/kWh)
Rs 1,5000
Savings per month Rs 4500
Annual savings Rs 54,000
Table 4.08:Benefits of load staggering
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CHAPTER 5
FINDINGS
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From the collected data it is found that the major energy consumption department is
melting department and to save energy from that must carried to save energy from furnaces.
As shown from power distribution tree that accordingly air compressors and electrical
distribution systems are also found major energy consumption areas in foundry after
furnaces. Savings in each department can be accomplished as per choosing best energy
management procedure.
For proper energy management system it would be necessary to choose an efficient
furnace that must be satisfy demand of foundry. Although high energy expenses are a
significant concern for metal casters, many foundries are using melting technologies with
poor energy efficiency. The amount of heat put into the furnace, the thermal efficiency refers
to the percentage of that heat that actually melts the metal. The remaining heat is lost,
through for example, inefficient combustion, the furnaces housing and flue
Supply of the full power during the melting (most of the time) is being practiced.
To lower the specific energy consumption, Reduction in time taken for sampleanalysis & communication was significantly reduced the heat time. Use of intercoms
and alarms, pneumatic conveying and advanced logistical preparations helped to
reduce the time for sample analysis.
In addition to above, use of recently introduced energy optimizer for meltingoperation created a benchmark and enforced conscious practice to complete the job
within the set goal. This energy optimizer senses the inverter output power and
integrates into energy delivered to the furnace. It is possible to set a predetermined
energy requirement value for melting the material to the desired temperature.
For proper energy management, Setting of energy parameter was based on lowestachieved energy consumption figure during the past fortnight. Close monitoring of
set goal and analysis of the reasons for not being able to comply with the
benchmarking if any, shall ensure reaching the optimum level of energy
consumption.
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CHAPTER 6
CONCLUSIONS
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There is a large scope of energy management in foundry industry sector in Indian
small and medium scale foundry industries considering the fact that the large amount of
power is being wasted by many ways. As majority of these foundries are not aware of
these facts.
From above we conclude that the better energy management program may save not
only in terms of energy but also it may save money. Savings of at least 10% and up to
40 % may be realized by implementing some useful energy management techniques.
The key to achieving savings is to take a strategic approach to managing energy use and
giving importance to energy management techniques. While energy efficient
technologies have a significant role to play in reducing energy use in foundry industry.
Most of the small-scale foundry units are family owned and managed. The general
level of awareness among them about energy conservation and new technologies is low.
Although some of the entrepreneurs are interested in energy efficiency and technological
improvements they are constrained by lack of technical know-how and finances.
Looking into todays scenario, it becomes very essential for Foundry men to look for
means which can bring down the energy consumption in melting operation significantly
by efficient methods and techniques
Success of Energy management depends on a team effort starting with a firm
commitment from the top executive and management team. The first assignment in
energy saving activity must be the initial energy audit. It is a key step that establishes
the baseline from which the future energy efficiency improvements can be measured.
One of the main results of energy audit is the possibility of determination of the energy
consumption pattern. The energy pattern is the key in understanding the way energy is
used in a foundry and helps to control energy cost by identifying areas where waste can
occur and where scope for improvement may be possible.
The best available energy management techniques needs to be used in order to
optimise the production. It is expected that there will be ample scope for Indian foundry
operators in energy management
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CHAPTER 7
RECOMMENDATIONS
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This would break new ground in energy-efficiency studies of the foundry industry;
it would produce the first process-oriented energy consumption database that considers
more than just melting energy; and it would generate Energy balances describing
foundry-process energy consumption that reflects the current state of the foundry
industry.
Specifically, the recommended survey project would
Survey all foundries with a written questionnaire. Conduct in-depth energy audits and energy analyses at six to eight foundries. Assimilate and analyse survey and audit data to develop a process-level energy
balance for foundry energy consumption.
Develop a utility tool that field representatives could use to conduct foundrycustomer energy-efficiency analyses at the process end-use level.
If appropriate, determine the energy use that goes into each process step bymonitoring actual energy input and material throughput as part of the energy audits.
Develop a baseline from which foundry utilities can offer a service to quantifyfoundry customer energy consumption as compared to the baseline.
Involve utilities in the study so they can follow-up with specific performanceoptimization proposals. The proposals could lead to case-study examples of foundry
efficiency improvements with before and after results.
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BIBLIOGRAPHY
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1 Barney L. Cape Hart, Wayne C. Turner and William J. Kennedy, Guide to energymanagement.
2 Energy conservation measures in the Foundry sector, Published by: WinrockInternational India, 2010.
3 Chapman, L. R. and Stark, R. 1990. How to Organize an Energy ManagementEffort. Iron and Steel Engineer.
4 Cluster Profile Report Kolhapur Foundry Industry.5 Manufacturing Energy Consumption Survey, Office of Industrial Technology,
Department of Energy, 1998.
Website:
1 Foundry informatics centre. (http://www.foundryinfo-india.org).2 The institute of Indian foundry men (http://www.indianfoundry.org.).3 www.soundcasting.com.4 http://www.energymanagertraining.com/Journal/latesttrend%20greenbusinessc
entre.pdf.
http://www.foundryinfo-india.org/http://www.indianfoundry.org/http://www.indianfoundry.org/http://www.foundryinfo-india.org/