Latest trends in ENERGY EFFICIENCY – Foundry Industry
Brakes India Limited Foundry Division
1
Methodology for energy conservation Steps
Activities
Step – 1
Map a power distribution tree.
Step – 2
Prioritizing the major energy consumers. Analyze the consumption pattern and arrive at specific energy
Step – 3 conservation themes. Step – 4
Implementation of the activities.
Step – 5
Review and sustain the benefits.
2
Power distribution tree Transmission losses 3.47 %
Input Power 100%
Available Power after loss 96.53 %
Melting 83.25 %
Furnace 78.76%
Melting 69.52%
Environmental control 5.33 %
Utilities 2.97%
Auxiliary 4.49%
Holding 9.24%
Moulding 2.80 %
Sand plant 1.0%
Cooling pumps 3.86%
Crane & Hoist 0.63%
Finishing 2.18%
Mixer 1.80 %
3
Prioritization of major energy consumer 100 80 60 40 20 0
Melting
Environment
Utilities
Moulding
Finishing
Energy (kWh) = Power (kW) X Time (Hour) Melting energy can be conserved by reducing
Input power
Cycle time 4
Cycle time of individual activities during melting operation Composition & temperature adjustment
Deslagging
Tapping
Charging
Melting
Reduce these activities
5
To reduce charging time By automation through vibratory feeders Before
Charging manually with magnet
After
Vibro chargers for faster & continuous charging
6
To reduce melting time 1. By improving the input power density Before
Only manual On / Off control
After
Melt manager to track the changing impedance to deliver optimum power throughout the melting cycle. 7
To reduce melting time 2. By improving the bulk density of the input materials. Before
Loose steel
Low bulk density
After
Bundled steel
Snap cutter for compacting the Runners
Higher bulk density 8
To reduce melting time 3. By reducing the radiation losses. Before
Furnace without hood
After
Furnace with closed capture hood 9
To reduce time for composition adjustment By exactly weighing & charging the input materials
Charge hopper and furnace on load cells to achieve right composition at the first check. 10
To reduce de-slagging time 1. By using clean input charge materials.
Online shot basting machine
Shot blasted runners & risers to minimize slag generation 11
To reduce de-slagging time 2. By easing the method of de-slagging (back tilting) Before
Manual slag removal
After
Quick slag removal through back tilting mechanism 12
To reduce tapping time By tapping all the metal at a single stretch. Before
Batch type transfer through ladles
After
Single stretch transfer through launder system Also, no power used for cranes, ladle heating etc13
To avoid superheating of metal By Online monitoring & controlling of tapping temperature Before
Contact type measurement through thermocouple
After
Continuous monitor through Infra Red pyrometer 14
Best practice in melting Control of Sintering cycle through automatic sintering cycle timer.
15
Best lining practice in melting Dense lining through pneumatic ramming for improved lining life Before
Manual Ramming
After
Pneumatic Ramming 16
Best lining practice in melting Pneumatic lining push out mechanism for lining breakage Before
After
Manual breakage
Faster breaking by lining push out
Minimum 12 hrs
Maximum 3 hrs
17
Best practice in melting Maximize the continuous utilization of the furnaces Before
After
Continuous usage of a single furnace to achieve the required output and optimized lining life 18
Best practice in melting By introducing harmonics filters
Reduction of harmonics in the power system thereby minimizing the transmission losses
19
Prioritization of major energy consumer 100 80 60 40 20 0
Melting
Environment
Utilities
Moulding
Finishing
Moulding 1. Reduce energy consumption in sand plant. 2. Reduce the mixer energy consumption
20
Best practice in molding By minimizing the number of conveyors in sand plant during the design stage Before
25 conveyor
After
16 conveyors
21
Best practice in molding By minimizing the number of conveyors in sand plant Before
After
3
2
1
1 3 conveyors
1 conveyor
22
Improved practice in molding By optimizing mixing cycle time by improving the efficiency of the mixer Before
After GHT EASED 0 mm
OP
SAND LEVEL
SAND LEVEL
<-----CURVED ARM BLADES
Blender blades – manufacturer’s design
M
<-----CURVED ARM BLADES
Lowered blender blades 23 for better mixing efficiency
Prioritization of major energy consumer 100 80 60 40 20 0
Melting
Environment
Utilities
Moulding
Finishing
Utilities Reduce energy consumption by the compressors Regulate the input voltage to the circuit
LIGHTING WHEN IT IS BRIGHT SWITCH OFF THE LIGHT
24
Optimize utilization of compressed air
Intermediate diaphragm controlled pressure regulator to supply 25 compressed air at constant pressure
Optimize utilization of compressed air Demand analysis 105 100
90 85 80 75
13:50
13:30
13:10
70 12:50
P si
95
H o u rs A fter
B efo re 26
Best practice in compressors Screw compressors with variable frequency drive in the design stage Before
After
Balanced opposed reciprocating compressor
Screw compressors
More energy consumption / CFM
27 Less energy consumption / CFM
Best practice in lighting Servo controlled lighting stabilizer for controlling the input voltage
28
GREEN POWER
! Installed 59 windmills. ! Each windmill capacity is 250 kW. ! Wind energy consumed in this year is 15 million kWh. ! 25% of power requirement of Foundry is met by wind power.
29
We have installed equipments for creating congenial & eco-friendly work environment that consume around 5.33% of the total input power.
30
We have installed equipments for creating congenial & eco-friendly work environment that consume around 5.33% of the total input power.
Rain water harvesting tank
Dust collector 31
Energy conservation proposals in progress â&#x20AC;Ś. 1. Installing a shredding machine for increasing the bulk density of the input charge
2. Preheating the charge material to reduce melting energy
3. Usage of eco friendly high calorific SKO instead of LDO
4. Installing magnetic resonators in the fuel line for high efficiency.
5. High efficiency fan for blowers and cooling towers. 32
Energy Consumption Melting
kWh / Ton of metal
650 600 550 500
602
571
Benchmark
Current
450 400
Period
33
Energy Consumption Auxiliaries - Melting
kWh / Ton of metal
200
175
150
125
163
146
100 Benchmark
Current
Period
34
Energy Consumption Moulding
kWh / Ton of metal
30
20 26 21
10 Benchmark
Current
Period
35
Energy Consumption Utilities
kWh / Ton of metal
30
20
27 22
10 Benchmark
Current
Period
36
Overall specific energy consumption
kWh / Ton of metal
950
900
850
920 862
800
750 Benchmark
Current
Period
37
ENVIRONMENTAL IMPROVEMENT S usp end ed p articulate m atter (S P M )
m icro g ram s / cu . m ete r
500
400
300
200
414
100 15 9 0 B en ch m ark
C u rren t
P erio d
38
CONSERVE ENERGY TODAY
AVOID CRISIS TOMORROW
39
Thank You 40