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Energy Savings in Foundries through Yield Improvement and Defect Reduction in Castings

Treść / Zawartość
Identyfikatory
Warianty tytułu
Języki publikacji
EN
Abstrakty
EN
Energy conservation is an important step to overcome the energy crisis and prevent environmental pollution. Casting industry is a major consumer of energy among all the industries. The distribution of electrical energy consumed in all the departments of the foundry is presented. Nearly 70% of the energy is consumed especially in the melting department alone. Production of casting involves number of process variables. Even though lot of efforts has been taken to prevent defects, it occurs in the casting due to variables present in the process. This paper focuses the energy saving by improving the casting yield and by reducing the rejections. Furthermore an analysis is made on power consumption for melting in the induction furnace to produce defective castings and improvement in the casting yield. The energy consumed to produce defective castings in all other departments is also presented. This analysis reveals that without any further investment in the foundry, it is possible to save 3248.15 kWh of energy by reducing the rejections as well as by improving the casting yield. The redesign of the feeding system and the reduced major rejection shrinkage in the body casting improved the casting yield from 56% to 72% and also the effective yield from 12.89% to 66.80%.
Rocznik
Strony
15--18
Opis fizyczny
Bibliogr. 20 poz., fot., rys., tab.
Twórcy
  • Sri Ramakrishna Institute of Technology, Department of Mechanical Engineering, Coimbatore, India
autor
  • Sri Ramakrishna Institute of Technology, Department of Mechanical Engineering, Coimbatore, India
  • Sri Ramakrishna Institute of Technology, Department of Mechanical Engineering, Coimbatore, India
autor
  • Sri Ramakrishna Institute of Technology, Department of Mechanical Engineering, Coimbatore, India
autor
  • Sri Ramakrishna Institute of Technology, Department of Mechanical Engineering, Coimbatore, India
Bibliografia
  • [1] Mathew, K.C., Roy Choudhry, P.K., Singh, R.J. & Harjit Singh. (1980). Prospects on saving energies in foundries. Indian Foundry Journal. 26(9).
  • [2] Arasu, M., Rogers Jeffrey, L. (2009). Energy consumption studies in cast iron foundries. Transactions of 57th IFC 2009, Kolkata, India.
  • [3] Chokkalingam, B. & Sadagopan, P. (2009). An analysis of energy loss through excessive scrap in foundries. Technology Trends. 42-44.
  • [4] CII,(1998). Report on Specific Energy Consumption Norms in Foundry Industry, 6-20.
  • [5] Datta, G.L. (1999). Energy management and audit in foundries. Training Manual. 5-40.
  • [6] Norberto, T., Downes, R., Duque, R.D. & Kannan S. (2005). Ten steps to improving casting yield. Ductile Iron Foundries. 3, 40-46.
  • [7] Borowiecki, B. Borowiecka, O. & Szkodzinka, E. (2011). Casting defect analysis by the pareto
  • [8] Sundararajan, S. (1989). Energy Conservation in Foundry Industry, Foundry Engineering Hand Book, Utility Publications Limited, 301-308.
  • [9] Abhilash E., Joseph. M.A. (2008). Studies on Energy Consumption of Melting Furnaces and Energy Conservation Options in Foundries. Energy. NIT Calicut.
  • [10] Seminar on Energy Conservation In Iron Casting Industry. UNIDO. The Energy conservation Center, Japan (ECC), Hanoi, 1998.
  • [11] Selvaraj, J. Ramachandran, K.I. & Keshore. D. (2013). A Novel Approach For Energy Conservation By Raw Material Preheating In Green Sand Casting. International Journal of ChemTech Research. 5(2), 871-879.
  • [12] Jarża, S. (2011). Importance of Energy Management in Foundries. Polish Journal of Management Studies. 4, 166-173.
  • [13] Patang, G. & Khond, M. (2013). Some Studies On Energy Consumptions and Identification of Suitable Energy Management Techniques in Indian Foundry Industries, European Scientific Journal. 9(24).
  • [14] Patange, G. & Khond M. (2016). Energy Efficiency in Small and medium Scale Foundry Industry, Metalurgija. 55(2), 257-259.
  • [15] Lazzarin, R.M. & Noro, M. (2015). Energy efficiency opportunities in the production process of cast iron foundries: An experience in Italy. Applied Thermal Engineering. 90, 509-520.
  • [16] Chokkalingam, B., Raja, V., Anburaj, J., Immanual, R. & Dhineshkumar, M. (2017). Investigation of Shrinkage Defect in Castings by Quantitative Ishikawa Diagram. Archives of Foundry Engineering. 17(1), 174-178. DOI: 10.1515/afe-2017-0032.
  • [17] Zhou, G. (2005). Analysis of Reasons Causing Riser Feeding Failure in Nodular Iron Castings Production. China Foundry. 2(2), 231-238. DOI: 1672-6421200504-0231-08.
  • [18] Chokkalingam, B. & Nazirudeen, S.S.M. (2009). Analysis of Casting Defect Through Defect Diagnostic Study Approach. Journal of Engineering Annals of Faculty of Engineering Hunedoara. 72, 209-212.
  • [19] B. Chokkalingam, L.M. Lakshmanan, L.M. & Sidarthan, I.V. (2006). Elimination of Defects and Increasing the Yield of a Ductile Iron Casting by Redesigning the Feeding System. Indian Foundry Journal. 52(6), 25-29.
  • [20] Sorel Metal (2000). Ductile Iron The Essentials of Gating and Risering System Design. Rio Tintito. Iron and Titanium Inc.
Uwagi
PL
Opracowanie rekordu w ramach umowy 509/P-DUN/2018 ze środków MNiSW przeznaczonych na działalność upowszechniającą naukę (2018).
Typ dokumentu
Bibliografia
Identyfikator YADDA
bwmeta1.element.baztech-4ed3319b-86a5-4ebf-85f5-bf33b7bce38d
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