A number of efforts have been made by suppliers of sand binders to reduce emissions without sacrificing casting quality.
team can begin to mea- sure and track energy use. It is important that clear metrics that encompass all energy utilized in the facility are used to mea- sure progress. A common metric correlates energy units and products, such as KwH per ton of castings shipped. If the metalcasting facility is using both gas and electricity, a single unit can be created. For example, cubic feet of natural gas can be converted to KwH, or both units can be converted to Btu. Set goals and develop a plan. Each metalcaster should immediately set goals for reduction. A 10% reduction over five years is suggested by some regulatory agencies. Te energy team should look for energy reduction opportunities throughout the operation. Although melting is the major point of use, significant savings can be seen in HVAC, ven- tilation, air compressors and lighting, as well as other areas. One study showed that an improved ventilation hood design can reduce static pressure and require as much as 50-75% less horsepower to operate. Evaluate progress and celebrate success. Each new energy
saving program should be carefully monitored so the reduc- tion in consumption is clearly defined and communicated. Celebrating and publicizing the achievement of energy reduction goals is an important step in changing the inter- nal company culture to be more energy conscious. Many metalcasters have done this by recognizing individuals that suggest energy saving ideas or hosting a public event to focus on achievements.
Areas for Improvement Metalcasters should examine the following areas of their
facilities to find places to reduce energy consumption.
Melting Buying the right scrap can net energy savings before melt-
ing materials are received at the metalcasting facility. Ferrous casting facilities have been comfortable receiving post-con- sumer steel scrap that contains surface rust, paint, adhering non-metallics and other non-steel attachments. Sheared scrap can contain 5-8% by weight of tramp non-metallic materials. It takes 1.7 to two times more energy to melt slag than it does to melt iron. By purchasing clean scrap created by shredding rather than shearing, a metalcaster can reduce energy consumption by 15-20%. Further melt savings can be achieved by cleaning gates
and risers of sand by passing them through a rotary drum or shot blast equipment. Keeping scrap yard sand/dirt to a mini-
一個數字的努力作出了供應 商的砂粘結劑，減少排放， 而不會犧牲鑄件質量。
能源团队可以开始测量 和跟踪能源消耗。一个 包含工厂中所有使用能 源的清晰法则对测量进 程非常重要。一个共同 的度量单位可以把能源 单位和产品关联起来， 例如铸件的千瓦时每
吨。如果金属铸造厂使用气和电，可以创建一个单一单 位。例如，每立方英尺的天然气可以转换成千瓦时，或 者两个单位都可以转换成英制热量单位。 设定目标和制定计划。每个金属制造商应该马上为 能源减少设定目标。一些监管机构建议把目标设定五年 降低10%。能源团队应该从整个操作中寻找能源降低机 会。尽管熔化金属时能源消耗最大，但在采暖、通风、 空调、照明以及其他方面可以有重大的节约。一个研 究显示，改进通风罩设计可以减少静压，差不多能降低 50%-70%的马力来操作。 评价进展和庆祝成功。每一个新的能源节约项目都应 该仔细地监控，这样可以很清楚地说明和传达消耗的减 少。庆祝和宣扬能源减少目标的成就是很重要的一步， 可以改变公司内部文化和让公司更有能源节约意识。许 多公司通过认可提出能源节约主意的个人或者举办以能 源节约成就为主题的公开事件来宣扬。
可以改进的范畴
金属铸造商应该检查他们工厂的以下方面来寻找可以 减少能源消耗的地方。 熔融金属
金属铸造厂收到熔融材料之前购买合适的废料可以 净节省能源。黑色金属铸造厂已经很适合接收用过后的 废钢铁，这些废钢铁表面有铁锈，油漆，粘结非金属和 其他非铁物质。熔炼炉渣使用的能源是熔炼铁的1.7到2 倍。通过购买粉碎的干净废料而不是剪切的废料，金属 铸造商可以减少15%-20%的能源消耗。 此外把废料通过旋转的滚筒或者喷丸清理设备进行清理
Summer 2011
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