or ISO TS16949 system for the auto industry, and implement lean manufacturing and information management systems with modules for sales, production, inventory, labor, salary and cost. However, a few companies still need improvement.
Efforts for Environmental Protection and Energy Saving
During investment casting production, exhaust can come
from rinsing waste, dust, dewaxing liquid and spent wax in wax patternmaking. It can also originate from fluke and waste shells in baking and melting, chemical liquid, waste- water, and acidic or basic fog in alkaline bursting and acid rinsing. Recently, more attention has been paid to environ- mental protection. As experiences are gained, new equip- ment has been developed, including the following items: 1. Water disposal equipment—Many companies have con- structed wastewater disposal systems for the acid rinsing of investment castings.
2. Shell recycling equipment—Shell recycling equipment can crush the shell and then remove dust. The recycled sand after disposal of magnetic separation can be used for back layers in shell making.
3 Dust removal equipment—Traditional baghouse dust col- lector equipment is susceptible to bag clogging with seri- ous dust pollution at worksites and is difficult to maintain. Some equipment manufacturers make water curtain dust removal machinery, which realize good results in shell making lines.
4. Replacement of oil or gas shell baking with an electric oven—This equipment reduces the release of fluke.
5. Specially designed equipment for gathering chemical waste fluid, wax, acid fog, alkali fog, etc.—The gathered waste can be disposed in batches. Ways to decrease energy use in shell baking include:
1. Innovation of oven design—Single chamber ovens have been reformed to dual chamber structures. Circular chamber ovens are used in mass production enterprises. Therefore, fuel consumption is decreased by 50%.
2. Change of heating method—Electricity is used to replace oil or gas burning ovens to save energy. With regard to electric ovens, electric resistance or silicon carbide bars are used.
3. Increasing heat insulation of ovens—The application of aluminum silicate felt can keep the outer surface tem- perature lower than 40C (104F), so energy is saved at the same time working conditions are improved.
4. Use of residual heat—Some enterprises manage to use the residual heat released by castings after pouring. Ways to reducing energy consumption in melting include:
1. Use of high frequency induction furnaces. 2. Selection of optimal volume of the induction furnaces. The volume of an induction furnace is expanded to satisfy the increase in melt consumption by increasing each shell volume to 150-200 kg (331-441 lbs.).
3. Management of electricity use. A card electric meter is installed on induction furnaces to force operators to monitor consumption. ■
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烧和熔化的烟气、废型壳、碱爆和酸洗排出的化学废 液、废水、酸碱雾等。近几年来我国熔模精铸业越来越 重视环境治理，摸索和创造了一些成功治理的经验，并 开发了一些成熟的设备，具体包括： 1. 水处理 不少企业陆续建立了废水处理系统，使用适 合于精铸件酸洗钝化废水处理的专用设备。 2. 型壳回收 对废型壳进行回收处理得到更多企业重 视。通过破碎筛分、除尘、磁选后的再生砂粉，经生 产验证，可以作背层制壳材料。有关设备厂已生产出 型壳回收设备。
3. 除尘 布袋式除尘设备在粉尘量大的作业区工作时， 布袋易堵塞，维护工作量大。有的公司在制壳线上采 用水幕除尘。设备厂也开发了水幕除尘设备，取得良 好的除尘效果。
4. 用电炉代替燃油和煤气焙烧炉 用电炉代替燃油和煤 气焙烧炉壳减少烟气排放。
5. 对化学废液、废蜡、酸雾、碱雾等设专门的收集装 置，加强管理，集中处理。
节能降耗已经成为国家工业发展的战略决策，各企业 也充分给予了重视，并针对能耗大的工序采取了一些具 体措施： 1. 改造炉型 将单室箱室焙烧炉改为双室焙烧炉。产量 较大的企业采用环形回转炉，从而大幅度降低燃料消 耗，节能效果可达50％。 2. 改变加热能源 用电能代替燃油或煤气有利于节能。 电炉可采用电阻炉或硅炭棒加热炉。 3. 提高炉子保温效果 如采用硅酸铝棉作保温材料可 使炉外壁温度降到40℃以下，既节能又改善车间劳 动环境。
4. 利用余热 有的企业还在尝试回收利用浇注后铸件散 发的大量热能。
降低金属熔化能耗的途径
1. 选用节能技术先进的中频感应电炉 2. 选择感应电炉的最佳容量 通过扩大每个模壳的钢水 重量，从而扩大感应炉的容量，使之达到150至200 公斤，除提高生产效率外还同时达到节电的作用。 3. 加强用电管理 在感应炉上安装卡式电表，实行按炉 考核电耗，促使操作者精心控制，实现最佳的节电 操作。
提高铸件的工艺出品率、降低废品率是节能的重要途 径 重视浇注系统设计，在保证铸件质量的前提下努力提 高工艺出品率。严格控制生产工艺，降低废品率。 ■
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Summer 2011
FOUNDRY-PLANET.COM | MODERN CASTING | CHINA FOUNDRY ASSOCIATION | 41
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