Adapting Energy Efficient & Resource Efficient Technologies in Foundries Manish Kothari – Managing Director
Rhino Machines Pvt Ltd Anand, Gujarat, India. 22nd July 2022 At Workshop Organised by UNIDO – BEE - GEF
Creating a Greener Sustainable Future for Foundries
Moulding Process – 2nd Highest Energy Consumer Sand Resin
CORE Lighting 5%
Gas
Temperature Measurement
METAL
70%
Compressed Air 10%
5%
FETTLING
Lining Inspection & Painting
Mould
Alloys
7%
Metallic
Shots
Grinding Wheels Bentonite
Discard
Sand
Coal Dust Water
SAND
Reclaim
Dispatch
Energy Consumption in Green Sand Moulding
Green Sand Management
Green Sand Moulding
Silica Sand Management
Mould Making
Sand Reclamation
Mould Handing
Sand & Dust Disposal Management
Sand Mixing Sand Cooling
Sand Conveying Dust Collection
Sand Mixers – Energy Consumption Specific Power Consumption kW/MT for Popularly Known Mixers
Fixed Rotor, Fixed Rotor, Fixed Fixed Tank Mixer - Muller Tank Intensive Mixer Intensive Mixer (Slow Speed) (High Speed) Batch (kgs) Process Time (sec) Output kg/hr Power (kW) Utilisation Power Consumed kW/hr Specific Power Consumption kW/MT
Rotating Tank, Fixed Rotor, Planteary Mixer
Fixed Tank, Planetary Tools with VFD
220 360 2,200 7.5 85% 6.375
250 180 5,000 13 85% 11.05
500 100 18,000 67.5 85% 57.375
760 120 22,800 68.5 85% 58.225
500 140 12,857 33 NA NA
2.90
2.21
3.19
2.55
1.60
Sand Cooler – Energy Consumption Specific Power Consumption kW/MT for Popularly Known Sand Coolers
Rotary Drum Evaporative Cooling Output kg/hr Power (kW) - only cooling Utilisation Power Consumed kW/hr Specific Power Consumption kW/MT
Fluidised Bed with Mixer cum Cooler Eight Type Cooler Heat Exchanger Evaporative Evaporative Cooling Tubes Cooling
10,000
1,000
22,000
20,000
7.5
18.5
44
11
85% 6.375
85% 15.725
85% 37.4
85% 9.35
0.64
15.73
1.70
0.47
Bucket Elevator Plant
Dust Collector
No of Drives : 21 : 386 HP Dust: 9 Places : 75 HP
D12 D9
D4
D16
D10
D15
D5 D13
DC D17
D14
Moulding Centre
D6 D1
D7
D6 D10 D C
D11
D3
D2
Belt Conveyor Plant
40 MT/hr Sand Handling Plant
Handling– Bucket Elevator vs Belt Conveyor
No of Drives : 12 Dust: 4 Places
: 266 HP : 25 HP
D3 D4
D7
D C
D9
D8
Moulding Centre D1
D5 D2
D11
Comparison of Energy Utilisation Installed Power Pie Chart of 40 MT/hr Plant Conventional Bucket Elevator Sand Plant Power Distribution 461 HP
75 16.3%
Belt Conveyor Sand Plant Power Distribution - 291 HP
5.2% 5.2% Lower Dust Generation, Huge Reduction in Energy
15
15
Recirculation Cooling, Mixer Cooler – Reduce Cooling Energy
70 15.2%
132.5 28.7%
183.6 39.8% Sand Handling Sand Cooling
Sand Mixing Dust Collection
Reduced Sand Handling Energy
Sand Mixing More Energy for Real Work
67.0% 195
66 22.7%
Compressed Air v/s Fully Hydraulic Jolt Squeeze Machines Specific Squeeze Force 1.5Kg/cm2
No Safety
>110 dB 30 HP
Reduces Weight Improves Dimensional Accuracy Improves Global Competitiveness
High Pressure Moulding Specific Squeeze Force 10 kg/cm2 (6 times)
Energy saving 30% in Machine 50% in Machining 2% in Material Safe Working Conditions Safety as per International Standards Adheres to Pollution Norms
<85 dB
Safety Barrier
12.5 HP
Comparison Comp Air v/s Fully Hydraulic Process & Energy Economics 350 TPM FM v/s JSQ Weight reduction saving @ 2.5%
@ Rs 15,000/MT
Rs 12.6 Lakhs
Power Saving @0.2 kWh/mould (600x600 box)
@ Rs 8.0/kWh
Rs 17.28 Lakhs
Manpower Reduction in Process
@ Rs 15,000/man/month
Rs 5.40 Lakhs
Recurring saving year on year Rs. 35.28 Lakhs out of which 50% is from Direct Energy and 30% contributes directly to Melting Energy
REDUCING CARBON FOOTPRINTS SAND RECLAMATION
Reducing Carbon Footprint By Waste Recovery • Sand Reclamation plants for Green Sand affect 70% of the foundries i.e. 7 Million MT of Casting Production i.e. 2.1 Million MT of Sand • The Fossil fuel usage 10.5 Million litres and related carbon footprint by 23 Million kgs CO2 Emission
SILICA PLASTIC BLOCK
80% 20%
PROJECTED CONSUMPTION
3 Million MT/Year
12 Million MT/Year
CIRCULAR ECONOMY
LINEAR ECONOMY
TAKE USE RE-USE RECYCLE
MAKE
CONSUME
DISCARD
Silica Plastic Block
FOUNDRY
COMMUNITY
Silica Plastic Block
Diesel/Annum
Per Trip
We are expanding the ecosystem to future-proof our climate by reimaging the energy efficiency and waste realities.
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