Ductwork
Heat leakage in heated ductwork in the winter months might be considered acceptable as a supplemental heat source, but in the summer, it adds to the plant tempera- ture load and must be exhausted from the plant. Perform regular inspections on all ductwork and calculate the heat losses. Te value of insulating ductwork and piping will be recovered quickly.
Motors High-efficiency motors used in moldmaking can save
2-5% on operating energy. When considering the cost of high-efficiency motors, remember that the original purchase price will probably be no more than 5% of the operating cost of the motor over its lifespan. Te cost of electricity will be more than 95% of the cost of operation. In the case of re-winding motors, studies have shown that
rebuilding motors nearly always results in a motor that is not as efficient as the original purchased motor. If re-winding must be done, a carefully written set of
engineering instructions and procedures must be in place. Another consideration is using variable frequency motors
for operations that have widely varying loads throughout a cycle, such as in sand mulling.
Tis article is adapted from the paper, “How Can We Become a Practical Green Foundry Industry,” which was first presented at the 114th the Hoyt Memorial Lecture.
Metalcasting Congress as
part when it comes to chemistry, we have the opportunity to use more exotic materials.”
U.S. Foundry also looks for scrap coming from nearby sources, including scrap steel from the Orange Bowl stadium when it was torn down in 2008. Local sources of steel help the metalcasting facility and its customers earn credit through LEED, a green building certification program that encourages sustainable building and development practices. “We can receive LEED credit for pre- and post-consumer recycling and for using locally produced/locally supplied prod- ucts,” SanSolo said. U.S. Foundry works with its customers to provide evidence of recycled content and/or local supply to help them earn LEED certification.
U.S. Foundry also has found a way to help its customers become more environmentally friendly. Through a U.S. Envi- ronmental Protection Agency initiative, the National Pollutant Discharge Elimination System permit program, communities are obligated to instruct citizens on the harm of dumping something into waterways. U.S. Foundry offers to incorporate an emblem or message on a drainage casting at no charge as a reminder to industries not to dump. “It’s a permanent, low-cost way of discouraging dumping into communities,” SanSolo said.
—Shannon Wetzel, Senior Editor April 2011 MODERN CASTING | 41
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