energy requirements for typical green sand foundry sand-binder mixing core forming core curing mold...

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Energy Requirements for Typical Green Sand Foundry sand-binder mixing core forming core curing mold & core assembly mold pouring, cooling shakeout riser cutoff & gate removal cleaning, finishing, coating QA / shipping mold making sand renewal metal melting slag, dross removal scrap preparatio n 1.2-3.5 MJ/kg saleable casting 1.2 MJ/kg 0.7 MJ/kg Melting (MJ/kg) Cupola 6.7 Coke 1.3 Electricity 1.9 Natural Gas 0.1 Oxygen Electric melting 5.0-5.6 Induction 5.0-6.0 Electric Arc 6.0-9.2 Reverb Fuel fired melting 2.1-7.9 Crucible 2.9-5.8 Reverb

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Page 1: Energy Requirements for Typical Green Sand Foundry sand-binder mixing core forming core curing mold & core assembly mold pouring, cooling shakeout riser

Energy Requirements for Typical Green Sand Foundry

sand-binder mixing

core forming

core curing

mold & core assembly

mold pouring, cooling

shakeout

riser cutoff & gate removal

cleaning, finishing, coating

QA / shipping

mold making

sand renewal

metal melting

slag, dross removal

scrap preparation

1.2-3.5 MJ/kg saleable casting

1.2 MJ/kg

0.7 MJ/kg

Melting (MJ/kg)Cupola 6.7 Coke1.3 Electricity1.9 Natural Gas0.1 OxygenElectric melting5.0-5.6 Induction5.0-6.0 Electric Arc6.0-9.2 ReverbFuel fired melting 2.1-7.9 Crucible2.9-5.8 Reverb

Page 2: Energy Requirements for Typical Green Sand Foundry sand-binder mixing core forming core curing mold & core assembly mold pouring, cooling shakeout riser

Energy Requirements for Typical Green Sand Foundry By Mass Fuel

sand-binder mixing

core forming

core curing

mold & core assembly

mold pouring, cooling

shakeout

riser cutoff & gate removal

cleaning, finishing, coating

QA / shipping

mold making

sand renewal

metal melting

slag, dross removal

scrap preparation

100-300g fossil fuel/kg saleable casting

100 g/kg

60 g/kg

Melting (g/kg)Cupola 170 Coke120 Electricity50 Natural Gas5 OxygenElectric melting450-500 Induction450-550 Electric Arc550-800 ReverbFuel fired melting 50-200 Crucible73-150 Reverb

Page 3: Energy Requirements for Typical Green Sand Foundry sand-binder mixing core forming core curing mold & core assembly mold pouring, cooling shakeout riser

Fuel Requirements

• Using Williams’ conversion– 320 g fossil fuel/kWh electricity– 40 MJ/kg of nonelectric fuel

• 1 kilogram casting using EAF requires 900 g fossil fuel

• 1 kg casting using coke cupola requires 550 g fossil fuel– Disparities caused by efficiency of

electricity production, size(?)

23%

7%

12%

58%

Mold and sandpreparation

Pouring andshakeout

Finishing

Melting

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