Project for mba deepak desai.pdf

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CHAPTER 1

INTRODUCTION


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1.1 BACKGROUND OF THE STUDYThe Indian foundry industry is the second largest in the world. There are more than

6,000 foundries in India. Most foundries (nearly 90%) in India fall under the small and

medium scale category and are located in clusters.

The metal casting industry is naturally very energy intensive. Energy consumption

in foundry mainly depends on electricity. The energy efficiency of any metal casting

facility depends largely on the melting processes. Global warming is putting pressure on

policy makers to formulate and adopt energy policies aimed at different sectors of the

economy, industrial energy efficiency plays a central role in this regards.

Foundry consumes huge amount of energy, and yields tons of wastes. Foundry

industry is one of major energy consumption industry and exerts significant effect on

environment. Energy accounting is necessary to determine where and how energy is

being consumed and how efficient is the energy management system. Energy

conservation and emission reduction is related tightly with the survival and development

of the industry, and it is also a key point of sustainable development Foundry consumes

huge amount of energy, and yields tons of wastes.

Foundry uses two main forms of energy: coke and electricity. In a foundry usinginduction furnace for melting, electricity accounts for about 8595% of the total energy

consumption of the unit. Induction furnace is major electricity consuming equipment, it

consumes about 7085% of total electrical energy consumption. If the foundry units are

heat treating the castings then diesel consumption comes out to around 1525% of the

total energy consumption of the unit. In cupola-based units, coke typically accounts for

8590% of the total energy consumption of the unit.

The energy efficiency of foundry largely rides on the efficiency of the melting

process a multi-step operation where the metal is heated, treated, alloyed, and

transported into die or mold cavities to form a casting. The melting process is not only

responsible for the energy consumption and cost-effectiveness of producing the castings

but it is also critical to the control of quality, composition, and the physical and chemical

properties of the final product.


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1.2 COMPANY PROFILE

Soundcasting is a world class manufacturer of Grey Cast Iron and Ductile Iron

Machined Castings. With a built-up manufacturing area of 39,000 Sq. Meter, we have

fully integrated casting and machining operations run in environmentally friendly

foundries and machine shops. Our specialization is in supplying intricate, cored and fully

machined cast components in the weight range of 10-125 kg and in the volume range of

1,000-15,000 quantities per month to OEMs and system manufacturers. The installed

casting capacity is 5000 tons per month, including a capacity of 1800 tons via High

Pressure Moulding Line (DISAFLEX 70) installed in March 2010.

1.2.1 BOARD OF DIRECTORS

S.No Name of the Directors Designation1 Mr. V.N. Deshpande Executive Chairman2 Mr. N.S. Wagh Non-Executive Vice Chairman

3 Mr. U.K. Deshpande Executive Vice Chairman

4 Mr. Anand V. Deshpande Managing Director

5 Mr. Ravindra K. Kalkundri Joint Managing Director

6 Mr. Abhijeet V. Deshpande Joint Managing Director

Table 1.01: Board of Directors


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1 V.N. Deshpande(Executive Chairman and founder Director)

Mr. VN Deshpande, VN, as he is referred by his friends, is also

Chairman of Deshpande Automech Pvt. Ltd. Kolhapur, a company engaged

in manufacture of Engine and bar components. He is BE (Mech) and

PGDBM. He has past work experience in various industrial organizations in

the area of materials management, oversees technical collaboration, planning

and general management. While he has developed the organization through

various roles, he now takes interest in long term strategic planning, expansion

projects and key stake-holder relations.

2 N.S. Wagh(Non-Executive Vice-Chairman and founder Director)

Mr. Wagh is a BE Mech and BE Met and has a vast experience in the

foundry industry. He has headed various areas in the company including

HRD, marketing and operations. Currently he mentors the management team

on a monthly basis and is on certain board appointed committees.

3 U.K. Deshpande(Executive Vice Chairman and founder Director)

Mr. UK Deshpande has a mechanical engineering background and has

extensive experience in the areas of machining, ferrous casting and foundry

project implementation. He is the Chief Technical Officer and a sensi to the

technical team throughout the organization. Mr. UK Deshpande has led the

successful plant installation and commissioning of our recent HPML line.

4 Anand V. Deshpande(Managing Director)

Mr. Anand has a B Tech in Mechanical Engineering from IIT

Powai, MS in Industrial and Systems Engineering from The Ohio State

University and MBA from University of Akron USA. Anand has worked in

the USA for world class aerospace component manufacturer PPC airfoils

and automotive company Mascotech, a leader in forgings. After working in

the areas of product design and manufacturing he took over manufacturing

of the company in 2000.

He is responsible for creating the quality brand that Sound Castings

is known for today. The ISO 9000, QS 9000 and TS 16949 were taken in a


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short period of time and quality systems were strengthened over the decade

to provide PPM levels at customer end. Anand is a hands-on leader and his

primary focus area is Operations and Human Resource Development.

5 Ravindra K. Kalkundri(Joint Managing Director)

Mr. Ravi is a Chartered Accounted and in his previous career has

practised in several organization including EOU companies. He joined the

company full time in 1993. His acute financial acumen and discipline have

helped the company progress in a systematic and planned manner without

getting unduly leveraged. Ravi leads the finance, accounts and IT area within

the company.

6 Abhijeet V. Deshpande(Joint Managing Director)

Mr. Abhijeet is a Metallurgist and has MS in Net Shape

Manufacturing Systems from The Ohio State University. He also has an

MBA from University of Pittsburgh. Abhijeet has worked for Tier 1, world

class Die casting companies such as Ryobi and SPX Corporation in the USA.

He has experience in the area of customer service, product quality/

engineering and operations management. He is a certified Six Sigma Black

Belt. Abhijeet leads the product development and marketing functions in the

company.


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1.2.2 MANUFACTURINGFoundries

Soundcasting have State of the Art Foundries & Machine Shop at Kagal, Tardal and

Shiroli in Kolhapur.

MIDC Kagal KATP Ind Estate Tardal MIDC Shiroli

Plot area -

44,600 sq m.

Plot area101,171 sq

m.

Plot area7,965 sq m.

Built up area

25,000 sq m.

Built up area8,800 sq

m.

Built up area5,000 sq m.

Power

Connection

-7500 KVA

Power Connection -

5435 KVA

Power Connection -1500 KVA

Table 1.02: Foundry Detail

Present Total Capacity is 5000 MT/month

Fully Automated DISA Make High Pressure Moulding Line Foundry

Box size: 1000 mm x 700mm x 325/325 mm. 2.2 MVA, 750 Kg- 4 nos induction melting furnaces from Inductotherm India DISA make fully automated sand plants with 48MT / hour capacity Draft angles within 1 degree and mis-match within 0.5 mm PLC controlled Cold Box Core Shooters from 5 Kg to 100 Kg single piece

core

Cores dried in conveyor type ovens with appropriate temperature controls Automatic Core sand plants of 5MT/ hour to dry and process core sand Capability of casting modelling, gating design and access to simulation Environmental compliance via use of dust collectors, cyclones, scrubbers and

other pollution control equipments

In-mould cooling of 2 hours followed by 2 hours of air-cooling for largecastings

Spinner hanger type shot blasting machines for good shot coverage


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Mechanised conveyor type paint booth for uniform casting painting

Fully mechanized APRA 900 and ARPA 450 Foundry from DISA India

at Tardal

Box Size of ARPA 900 - 800 mm x 650mm x 225/350 mm. Box Size of ARPA 450 - 650 mm x 650mm x 200/275 mm. 3750 KVA , 2000 Kg3 nos induction melting furnaces from Inductotherm

India

Vibratory chargers and magnetic cranes for feeding furnaces Automatic Core sand plants of 3MT/ hour to dry and process core sand PLC controlled Cold Box Core Shooters from 5 Kg to 18 Kg single piece core

and 3 ton/hr. core oven, more are planned

DISA make fully automated sand plants with 40 MT / hour capacity Automated mould handling system with auto punch-out (knockout) system Spinner hanger type shot blasting machines for good shot coverage

Fully mechanized APRA 450 Foundry from DISA India at Kagal

Box Size of line 1 - 650 mm x 650mm x 175/300 mm. Box Size of line 2 - 650 mm x 650mm x 225/250 mm. 550 KVA , 500 Kg 3 nos induction melting Furnaces from Inductotherm

India

DISA make fully automated sand plants with 36 MT / hour capacity

Mechanized APRA 450/ 300 Foundry at Shiroli

Box Size of line 1 - 650 mm x 650mm x 150/325 mm. Box Size of line 2500mm x 500mm x 150/300 mm. 550 KVA , 500 Kg 3 nos induction melting Furnaces from Inductotherm

India

Sand Plant capacity of 24 MT/ hour


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Core Shops: Equipped with Core Sand plants, Cold Box core shooters

and Core drying ovens

Cold Box Core Shooters

(2)- 100 Kg core shooter (1)- 80 Kg horizontal core shooter (1)- 65 Kg core shooter (1)- 30 Kg core shooter (1)- 25 Kg horizontal core shooter (1)- 20 Kg core shooter (5)-18Kg core shooter (2)-15 Kg horizontal core shooter (6)- 5 Kg core shooter

Shot blasting & fettling / painting in-house facilities

Facilities in Machine Shop

Machine-shop space is available in all three locations and cumulative covered area is 8200 sq

mts.

A] Machining Centers

Horizontal Machining Centres14 nos From maximum pallet Size 800x600 mm (Mazak 6800) to minimum pallet Size

450x450 (Makino A 51)

Vertical Machining Centres- 9 Nos Vertical CNC Turning centres- 6Nos Horizontal CNC Turning centres- 2 Nos

B] Special Purpuse Machines (SPM's)- over 75 nos

C] General Purpose machines

Radial Drilling M/cs: RM 62, BVR 3 Milling M/cs: FN2, FN3 Tapping M/cs Vertical Balancing M/c

D]Common Facilities for Foundry & Machine shop

Electrical Power Connection7500 + 1500 + 5435 KVA

Diesel Generator250 KVA- 3 Nos


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1.2.3 QUALITY & TESTINGSoundcasting have a robust quality system certified to TS 16949 and ISO 9000 by

TUV Nord, an independent IATF approved body.

QC in Foundry:

Spectro-lab make spectrometer (2 nos) Tensile testing machine Microscope with image analyser Chemical testing (wet analysis) Hardness testing Casting sectioning and layout marking

Access to nationally certified labs for radiography, Dye-penetrant, and othertests

QC in Machine shops

3-D CNC controlled CMM (700x1000x600mm- Mitutoyo and Brown &Sharpe make),

1-D electronic height gauges- make Trimos and Tesa Optical profile projector Surface testers, various bore dial gauges, air and water leakage testing etc. All critical characteristics (process and product) monitored by run charts/ SPC PDCA cycle effectively used for root cause analysis of non-conformance Mistake proofing, frugal engineering, cross-functional team working and

continuous improvement are core to our manufacturing

Our goal is to surpass customer ppm target


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1.2.4 PRODUCTS

Figure 1.01: Engine Appilcation

Figure 1.02: Gearbox & Transmission


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Figure 1.03: Axle, chassis and Brake Systems

Figure1.04: Pump, Hydraulic Systems


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1.2.5 CUSTOMERS

Figure 1.05: Customers

Table 1.03: Customer Specific

1 Mahindra & MahindraLtd.- Automotive Sector

2 Mahindra & Mahindra Ltd.-Farm Equipment Sector

3 Mahindra Navy StarAutomotives Ltd

4 Ashok Leyland Ltd

5 John Deere Equipment PvtLtd

6 Kirloskar Oil Engines Ltd7 New Holland Tractors 8 Brakes India Ltd.9 ZF India Pvt Ltd. 10 Windals Precision11 Eicher tractors 12 Tafe


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1.2.6 MILESTONES1988:

Established as a foundry making only 50T per month by Mr. VN Deshpande,

UK Deshpande and Mr. NS Wagh.

1993:

Started Induction furnace melting by adding Inductotherm make furnace.

1998:

Merged Deshpande Industries, an independent machine shop with itself and

expanded the machining set-up.

2000-2006 :

Started various new process improvement and six-sigma initiatives, added

several new customers including Ashok Leyland, John Deere, Kirloskar Oil

Engines and Brakes India.

2007-2009:

Added a plant in Kagal MIDC, added several investments in foundry and

machining, added customers such as ZF and Case New Holland. Capacity

increased to 2200 MT per month.

2010:

Added High Pressure Moulding Line. New customers such as TAFE and Tata

Cummins limited were added, in addition to strengthening relations with

existing customers. Capacity added to 4000 MT/month

2011:

Added new machining Centers including those from MAKINO and MAZAK,

Japan.


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1.2.7 CONTACTSOUND CASTINGS PVT. LTD.

E-2, M.I.D.C., Shiroli, Kolhapur 416122

Maharashatra State, India

Phone +91-9623262099

Fax 91-230-2468219

[email protected]

Figure 1.06: Location Map
mailto:[email protected]:[email protected]:[email protected]:[email protected]


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1.3 STATEMENT OF THE PROBLEMUntil recently, in most industries energy costs were regarded simply as a cost

of doing business, and little attention was paid to them. The level of interest in efficient

energy use had been moderated by continuing low electricity and fuel prices that

prevailed until 2000.After 2000 due to price of electricity hike its added urgency to the

need to examine the effectiveness of energy use in Soundcasting.

1.4 NEED OF THE STUDYThe need of this study is to explore Grand Challenge or breakthrough

opportunities that might dramatically reduce energy consumptions and Identification to

potentially energy-saving based on the findings.

1.5 SCOPE OF THE STUDYThe scope of the study includes energy consumptions and identification to

potentially energy-saving applications in the metal casting industry in domestic markets.

Although, the report focuses on foundry applications, the energy management programs

discussed in this report are in general applicable to all casting industry and other

industries.

1.6 OBJECTIVES OF THE STUDY Determination of the energy consumption pattern. Helps to control energy cost by identifying areas where waste can occur and

where scope for improvement may be possible.

Finding energy management programs further.


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CHAPTER 2

LITERATURE REVIEW


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2.1 POWER DISTRIBUTION TREE OF FOUNDRYIn figure the main processes of foundry energy consumption is shown so that one

can understand the whole system step by step with power consumptions in different

departments and also the losses

Figure 2.01: Power distribution tree of FoundryThe foundry industry is one of the most energy-intensive industries accounting for

one-eighth of all the energy supplied to industries. Main foundry classes are Gray- and

ductile-iron foundries (Standard Industrial Classification code 3321), malleable-iron

foundries (SIC 3322), and steel foundries (SIC 3325)these represent more than 95 percent

of the total foundry energy consumption in Wisconsin.

The American Foundry mens Society Cast Iron Directory 1995-1996 lists 191

foundries in Wisconsin, of which about 154 fall into the three ferrous iron categories listed

above. Gray- and ductile-iron foundries account for more than half of this total, followed

closely by steel foundries. There are only three malleable-iron foundries listed. Although

many of Wisconsins ferrous foundries are relatively small, some high-volume plants are in


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production. One Wisconsin plant, for example, melts approximately 700 tons of metal per

day, and total daily energy consumption can reach 1000 kWh.

This study was designed to provide information that could be used to help identify

ways to improve process energy efficiency at foundries. To do this we performed an

extensive review of the literature to develop the consistent foundry information resource

presented through this report. This information is designed to provide utilities, government

agencies, and energy-service providers with the data they need to design and deliver

effective energy-saving programs for Wisconsin foundries.

2.2 CURRENT INFORMATION ON PROCESS ENERGYUSE

Among major processes, the melting process consumes the most energy in a foundry,

representing about 50 to 80 percent of the total energy required to produce a casting. Typical

energy-consumption values found in the literature for the three primary melting processes

for Gray iron are shown in Table

Figure 2.02: Energy consumption of melting processes (kWh per ton of casting sold)

These figures depend on casting efficiency. All castings have risers and runners that

are needed to produce a shrinkage-free product. Depending on how the casting is designed,

the quantity of returns can vary between 30 and 95 percent. This material is melted but does

not become a part of the finished casting. Hence, the energy used per ton of finished casting

can vary substantially with the efficiency of the foundry, the intricacy of the mold, and the

ability to reduce the quantity of metal returned.

Although foundry processes may appear to be relatively homogeneous when

compared with processes of other industries, significant variations between plants and

processes exist. The great diversity of thermal operations in a foundryresulting from the

different types of energy used, the working procedures used, production capacity, the nature

of alloys produced, the dimensions of castings heat treated, and the effective castings yield


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makes it difficult to establish an overall ratio of foundry energy consumption per ton of good

casting that would be significant to all foundries.

It has been difficult to develop average, typical, and best practice energy balances

for Wisconsin foundries because of a lack of published information on energy consumption

in specific foundry processes. Literature data tends to focus on the melting process; little or

no data are available on energy consumption in the other foundry processes. The bulk of the

information available is for Gray iron foundries, with limited data for ductile-iron,

malleable-iron, and steel foundries. Most data are for production prior to 1983. Since that

time, some foundries have taken steps to improve efficiency in the areas of yield

improvement, oxygen melting assistance, furnace and ladle insulation, and recovery of heat

previously discharged to atmosphere. As a result, Wisconsin foundries may be operating

more efficiently than indicated by most information sources.

2.3 INFORMATION DATABASE2.3.1 Developing Process Baselines

We collected information on the major melting processes common to

foundries. These data were often from highly detailed studies of foundry practicesand represent comprehensive information on foundry melting process energy

consumption. Energy consumption figures collected for processes other than melting

were less complete. The energy consumption data for melting processes were

obtained from compilations available in the literature.

2.3.2 Cupola Melting ProcessA major problem with comparing the coke consumption in cupolas is that

some of the coke input is used for adjusting the metallurgical composition of the

casting and is not combusted. Also, energy content of coke is variable and rarely

reported in the literature. We used an energy content of 22.72 million BTUs person

to convert coke consumption in cupolas reported in tons to energy units. We assumed

that all of the data reported are for coke consumption in conventional coke cupolas.

Coke less cupolas which use natural gas or oil as their primary fuel a re also

available. These newer types of technology are often used in duplexing operations


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combining coke less gas furnaces with electric induction holding furnaces. Many of

the literature sources do not specifically list the type of cupola or the fuel consumed.

About two-thirds of the data reported for cupola energy consumption are from

Canadian and British studies of cupola energy consumption. The Canadian study

(Warda et al, 1981) presents data from a detailed engineering study of thirty cupolas

conducted by the Canada Centre for Mineral and Energy Technology in the late

1970s. The British study (Energy Technology Support Unit, 1990a) draws on two

main sources of data; a recent questionnaire survey of the British foundry industry

conducted in 1989-90 and information from a British Cast Iron Research Association

study conducted in 1979.

We obtained only two data points for cupola melting energy in ductile-iron

foundries. One was from the British foundry survey (Energy Technology Support

Unit, 1991), and the other was from a Wisconsin foundry taken from a survey of

Wisconsin foundries (Leadon, 1984).We obtained only three data points for cupola

melting energy in malleable iron foundries (Energy Technology Support Unit,

1990a).

2.3.3 Induction Melting ProcessOne difficulty in comparing data for induction furnaces is the issue of

holding. Often medium frequency furnaces are installed as a pair, so that the melting

furnace can also perform the role of holding/pouring of molten iron after completing

each melt. Unlike the cupola and the mains induction furnace, the quoted energy

consumption would therefore include both the melting and holding/pouring

processes. Holding of molten iron following the mains and cupola melting processes

is most often accomplished by a channel induction furnace and energy consumption

data are often reported separately. According to data collected as part of the British

Energy Efficiency Office survey of coreless induction melting furnaces, (Energy

Technology Support Unit,1991), average energy consumption by mains frequency

induction furnaces was751 kWh/metric ton (681 kWh/US ton) of metal melted while

energy consumption in medium frequency installations was 818 kWh/metric ton

(742kWh/US ton). For reference, the theoretical electrical energy needed to melt cast-

iron and raise its temperature to 1450 C (2650 F) is about 419 kWh/metric ton(380

kWh/US ton). Considering coil and heat losses at about 20 to 25 percent, the

minimum energy consumption for highly efficient induction furnaces would-be about


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459 kWh/metric ton (416 kWh/US ton).More than half the data collected on induction

melting process energy consumption for this study comes from the British Energy

Efficiency Office survey. Data were obtained for only Gray-iron foundries and steel-

foundries. Figures for yield were not available; nor were overall energy intensity

figures for total foundry operations using induction melting processes. The majority

of the data for steel foundries were taken from the International Cast Metals Journal

(American Foundry mens Society, 1980), which gave only ranges of expected

energy intensities for steel induction melting processes rather than empirical data.

The one real data point (fora Wisconsin steel foundry) taken from the survey of

Wisconsin foundries (Leedom, 1984), is within 95percent of the theoretical minimum

energy intensity.

2.3.4 Duplex Melting ProcessThe most detailed data reported for duplex melting are from Leedom (1984)

fora foundry using a cupola and duplex process in two plants. There are two data

points each for ductile-iron and Gray-iron castings.

2.3.5 Electric-Arc Melting ProcessWe collected data for the arc melting process for Gray iron and steel. Most

of these data points were taken from Leedom (1984). All of the data for Gray ironis

10 to 15 years old. Data for arc melting for steel production contains both recent data

for state-of-the-art operations and older data from the early 1980s.

2.3.6 Induction Holding ProcessEnergy consumption data for induction holding processes was collected on

the basis of energy consumption per unit of metal throughput. Many variables

influence the energy intensity of holding a molten charge including technology,

continuous vs. intermittent operations, length of time required for holding, and

superheating as in a duplex/holding furnace. Information on these other important

variables was not provided in the literature along with the energy consumption

figure. We collected data for three different holding processes: duplex furnace,

channel induction furnace, and crucible furnace. The majority of the data collected

was for Gray iron, although we found two data points for ductile iron. All of the data

are between 10 and 15 years old. A few data points are from a Wisconsin foundry.


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2.4 INTERPRETING PROCESS ENERGY CONSUMPTIONESTIMATES

The figures presented in this report may overestimate energy consumption becausemany estimates were based on pre-1983 data. With the fall of real energy prices, energy

consumption in foundries has not been featured prominently in foundry literature. Since the

early 1970s, some foundries have taken steps to improve energy efficiency. The major

improvements have been in the areas of yield improvement, oxygen melting assistance,

furnace and ladle insulation, and recovery of heat previously discharged to atmosphere. On

the other hand, increases in pollution control apparatus have resulted in increased energy

consumption. Even so, Wisconsin foundries are probably operating more efficiently than

indicated by the outdated energy intensities available in the literature. We estimate that they

are as much as 25 percent more efficient than indicated by the pre-1983 figures. The data

shown for duplex process energy consumption must be viewed with extra caution. The data

were highly aggregated, and thus may not accurately represent actual energy consumption.


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CHAPTER 3

RESEARCH METHODOLOGY


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3.1 PROBLEM RECOGNITIONThis study is focused on determining the practical potential for reducing energy

requirements in the Soundcasting industry by looking at industry best practices, which

are referred to as best practice minimums. Both equipment design efficiencies and

operating procedures related to reduced-energy consumption are discussed in detail. The

highest energy consuming processes within each casting alloy family were investigated

to determine the potential for energy reduction measures.

The theoretical minimum energy requirements are also calculated for the major

energy consuming processes. The theoretical minimum energy requirements are

calculated by ignoring all energy losses and therefore are not achievable in practice. A

baseline of current foundry energy usage was also determined from the best available

information and is referred to as the industry average. The industry average energy

usage was then compared to the best practice to determine the potential for energy

reduction using existing and proven technologies and procedures.

Material and energy losses during process steps represent inefficiencies that waste

energy and increase the costs of melting operations. Modifying the design and/or

operation of any step in the melting process may affect the subsequent steps. It is,

therefore, important to examine the impact of all proposed modifications over the entire

melting process to ensure that energy improvement in one step is not translating to

energy burden in another step.

3.2 RESEARCH APPROACHAn energy management program follows the same principles that apply to

any purposeful undertaking (e.g., to quality and environmental management systems)

principles that Dr. Deming formulated as the four-step cycle, PlanDoCheckAct,

PDCA, shown below.


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.

Figure 3.01: Four key steps

The four stages of the PDSA cycle:

Plan - The change to be tested or implemented.

Do - Carry out the test or change.

Check- Data before and after the change and reflect on what was learned.

Act - Plan the next change cycle or full implementation.

To realize opportunities, foundry management must successfully integrate

organizational and behavioural (cultural) change and new energy use technology. The

energy efficiency effort must have a defined focus, accountability and responsibility.

The points in Figure are generic and given for information only. Their application will

vary with the size and complexity of a foundrys operations and will be determined by

site-specific conditions of a particular energy efficiency improvement program.

3.3 DATA COLLECTION METHODS3.4.3 Primary data

Primary data is the data that is collected for the first time i.e. the data did not

exist before the collection. In this report primary data has been produced by for

example finding energy usage across different utilities in company.

3.4.4 Secondary DataSecondary data consist of data which has been collected in another

context. In this report the data is collected from literature searches were

conducted to obtain available information on energy conservation in the

metal casting industry and from company annual report.


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Literature searches conducted for this study provided many

documents written by the metal casting industry and federal government

agencies. The specific documents referred to for relevant casting energy data

are listed in the reference section of this report. A significant study that

yielded very accurate energy data for a specific number of facilities is the

Energy Use in Select Metal casting Facilities, which was a quantitative

study that performed onsite measurement of energy use. The study gives

energy profiles for a cross section of casting facilities and was used along

with other foundry-specific studies.


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CHAPTER4

DATA PROCESSING AND ANALYSIS


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4.1 FOUNDRY TECHNOLOGIESThere are several types of equipment and technologies that are widely used in the

foundry process. Some of the major ones include:

Melting furnaces Sand mullers Intensive mixers Pneumatic grinders Shell moulding machine Core oven Shell core shooters

Knockout machine Shot blast machine

The major equipments are described below.

4.1.1Major equipment used in foundry units(a) Melting furnaces

Two types of melting furnaces are commonly used in a foundry cupola and induction furnace. While cupola uses coke to melt the metallic charge

materials, an induction furnace uses electrical energy. Although the energy cost

per tonne of molten metal is lower in a cupola, other advantages of induction

furnaces, viz., faster start-up, lower manpower requirement, and lower emissions

have contributed to their increasing popularity among foundry units in Kolhapur

cluster.

(b) Sand mullers

These are used for green sand preparation. Fresh sand is mixed with

bentonite and other additives and mixed in Muller to make green sand. These

usually come in small size of around 300 kg per batch, with typical connected

drive of 10 kW and cycle time come about 710 minutes.

(c) Intensive mixers

Cores are forms that are placed into the mold to create the interior

contours of the casting. They are typically made of clay-free silica sand mixture.

The sand is thoroughly mixed with suitable binders, water, and other ingredients


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in intensive mixers. This equipment basically has two motor drives, used to rotate

the blades and perform mixing. A typical 10 tonne per hour, 500 kg batch-

intensive mixture has a total connected load of around 70 kW.

(d) Shell-moulding machine

This is usually located below the sand mixer. Sand from a hopper falls

into the moulding box and then pneumatically or hydraulically pressed to make

the final mould. High pressure moulding machines can use moulding sand having

lower moisture contents and hence higher mould densities can be achieved. The

castings have better dimensional accuracy and better surface finish.

(e) Knock-out machine

The knock-out machine has grated base, and it has two vibrators one

on either side or a single vibrator.

(f) Shot blasting

There are different types of shot-blasting machines available; the

most common ones in Kolhapur foundry cluster are double door, two shooters

type. It has four drives, two for shooters, one of bucket rotating, and one for dust

collection. Typical 1 tonne per batch shot blast machine has total connected load

of around 25 kW.

4.2 FOUNDRY PROCESS DESCRIPTIONDifferent stages in manufacturing of a casting include the following:

4.2.1 Preparation of moulds and charge materialThis involves preparation of (i) moulding sand, (ii) casting moulds, and (iii)

charge (metals and alloys). Fresh sand is mixed with bentonite and other additives

and processed to prepare green sand, which is the most commonly used moulding

sand in Soundcasting, typical batch size varies between 200500 kg. The green sand

is then used to prepare moulds for the castings. Simultaneously, metal scrap, pig iron,

and other alloys are loaded in the furnace for melting. The ratio between raw

materials depends on final casting properties. A typical cast iron casting has raw

material in following percentage: metal scrap (25%), boring (60%), pig iron (10%),

and others (5%).


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4.2.2 Melting stageThe metal is then melted in either a cupola furnaceconventional or divided

blastor induction furnace. The typical temperature requirement for CI casting is

around 1500C, steel casting is around 1650C, and for aluminium casting 750C.Once the melting is completed, the molten metal is poured into the sand moulds using

a ladle operated either manually, automatically, or semi-automatically, that were

prepared in the first stage and allowed to cool down and harden.

4.2.3 Finishing stageOnce the metal has taken shape of the mould, it is removed, shot blasted, and

cleaned. It also goes through some machining, if required. The final product is tested

using spectrometer and packed for dispatch. Meanwhile, the sand from the mouldsis either disposed or treated in a sand reclamation plant for reuse. Units using sand

reclamation in Soundcasting are generally able to reuse about 80% of the sand. A

more technical illustration of the manufacturing process of a typical foundry unit in

the Soundcasting is presented in Figure.

Figure 4.01: Manufacturing process of a typical foundry unit in Soundcasting


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4.3 TYPES OF FUEL AND USAGE IN MSMES4.3.1Fuel types and quantity used in typical MSME units

Foundry uses two main forms of energy: coke and electricity. In a foundry

using induction furnace for melting, electricity accounts for about 8595% of the total

energy consumption of the unit. Induction furnace is major electricity consuming

equipment, it consumes about 7085% of total electrical energy consumption. If the

foundry units are heat treating the castings then diesel consumption comes out to around

1525% of the total energy consumption of the unit. In cupola-based units, coke

typically accounts for 8590% of the total energy consumption of the unit.

4.3.2Specifications and characteristicsCoke is used in foundries where the melting process is done in a cupola furnace

(conventional or divided blast) and electricity is used in units where melting is done in

an induction furnace. Other processes in a foundry such as sand preparation, machining,

shot blasting, etc., are all operated using electricity, irrespective of whether the foundry

is cupola based or induction based. Metallurgical coke is being used as fuel in cupola

based units in the cluster. The calorific value of the coke varies between 55006500

kcal/kg.

4.3.3Price/Tariff ElectricityThe price of electricity has increased from INR 5.90 per unit to INR 8.50 per unit in

Kolhapur. Figure 7 shows the trend over the last four years. The price shows an

increment of over 15% during this period.

Figure 4.02: Energy price (20092012)


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4.3.4CokeThe price of coke has increased over the last year and is presently about INR 30,000

per tonne.

4.3.5SourcesElectricity to Kolhapur is supplied from the Maharashtra State Electricity

Distribution Company Limited (MSEDCL). MSEDCL supplies electricity to 3.63 lakh

industrial consumers sourcing its power from thermal, hydro, gas, and non-conventional

sources like solar, wind, bagasse, etc. Coke is being supplied from various sources

which include Sesa-Kembla Goa, Gujarat NRE, and also from some suppliers in

Nagpur.

4.4 ENERGY CONSUMPTION PATTERN4.4.1 Utility-wise energy share

The share of energy usage across different utilities in Soundcasting foundry

is given. As shown, the majority of energy is consumed for the melting process

(about 70%). Moulding, core making, and sand preparation are also significant

consumers in the process.

Table 4.01: Utility-wise energy share in Soundcasting

It is observed that melting consumes a major portion of total energy consumed.

4.4.2 Energy consumption in melting furnacesA foundry had two medium frequency induction furnaces. The unit had fair

energy metering and reporting systems. Every melting furnace was connected to an

individual energy meter (average type). Every day the consumption and production


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of each furnace was recorded and monitored. The furnace details are presented in

table

Furnace

#

No of

crucibles

Crucible

Capacity,

kg.

Rated kW Rated

frequency,

Hz

Average

specific

consumption,

kWh/Mt

# 1 2 1000 &

1000

1000 500 674

# 2 3 500,500&

1000

550 100 777

Table 4.02:Furnace details with specific energy consumption

4.4.3 Energy consumption in CompressorsAir compressors were used in the machine shop for pneumatic equipment

and machine tools. While visited the foundry compressor system had found some

issues were presented below in table

Present system of Air compressor system

Location of the compressor was near

by the heat source that shown the

reason of rise in inlet temperature may

reduce power saving.

Measured temperature of inlet air is

about 45C by contact thermometer.

Regular checking of leak were not

taken place that cause pressure drops

that adversely affect the operation of

air-using equipment and tools,

reducing production efficiency.

Table 4.03:Present system of Air compressor system


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4.4.4 Present system of electrical distribution in foundryIt was found during visit that present electrical distribution system was not

proper with respect to timing and capacitor as presented in table

Present system of electrical distribution in

foundry.

No load is being shifted to Night

timing when the electricity is at low

cost.

There are no any capacitors using in

electrical system to maintain or

improve the power factor.

Table 4.04: Present system of electrical distribution

4.5 Energy management planTo start, a few major components must be put in place:

1. Firm commitment of top management2. Clearly defined program objectives

3. Organizational structure and definition of responsibilities

4. Provision of resourcespeople and money

5. Measures and tracking procedures

6. Regular progress review

Table 4.05: Energy management plan

Plan -Predict and prevent troubles beforehand.

Do -Educate and train employees.

-Implement the plans.

Check - Compare the results against the targets.

- When the results fall short, examine the causes.

- Take immediate measures.

- Analyze the process and identify the root causes and develop

Act -Revise the standards.


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4.5.1 Energy Saving Guideline Turn off lights (and other equipment) when not in use. High utility costs often

include paying for energy that is completely wasted.

Replace incandescent light bulbs with ENERGY STAR qualified compactfluorescent lamps (CFLs), wherever appropriate. CFLs cost about 75 percent

less to operate, and last about 10 times longer.

Adjust lighting to your actual needs; use free "daylight" during the day.

Turning off machines when they are not in use can result in enormous energysavings. There is a common misconception that screen savers reduce energy

use by monitors; they do not. Automatic switching to sleep mode or manually

turning monitors off is always the better energy-saving strategy.

To maximize savings with a laptop, put the AC adapter on a power strip thatcan be turned off (or will turn off automatically); the transformer in the AC

adapter draws power continuously, even when the laptop is not plugged into

the adapter.

Fix leaks of water. Small leaks add up to many gallons

Unplug battery chargers when the batteries are fully charged or the chargersare not in use.

Air ingress into the furnace (heat treatment furnace) causes significant lossof energy. All that extra air needs to be heated to maintain the proper furnace

chamber temperature. Air ingress may reduce cold spots and quality

problems as well.


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Figure 4.03: Radiation losses

The radiation losses are serious in melting furnaces (e.g., induction furnaces)where they occur through open lids, open dross removing or slagging doors,

from ladles with no or inadequate covers during heating, and especially

during molten metal transfer.

For thermal losses and conductive heat sinks, it is a question of adequateinsulation and furnace or ladle lining with the right type of refractory

materials. If dense firebrick is used for lining the furnace, it needs to be

installed in adequate thickness to limit the heat conductive losses.

Energy management is an ongoing concern in any foundry. Its success

depends on a team effort starting with a firm commitment from the top executive and

his or her management team. Managements demonstration of unwavering, solid and

visible support filters through the organization to each employee. Everybody will

take heed and will follow the example. Once the decision to manage energy has been

reached, it should be supported by a board-level energy policy, which will regard

energy and the cost of utilities as direct costs on par with other operational costs,

such as labour, raw materials, etc.

A build-up of general awareness about energy issues through

communication, education and training of employees at all relevant levels will

contribute to a cultural change within the organization. Education and training must

be sustained in order to achieve lasting energy efficiency improvements. Sometimes,

even when the opportunities for energy savings are great, they are not utilized.


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The reasons fall into the familiar:

Was not aware of opportunities that exist;

Did not know what to do;

Top management not supportive;

Energy issues not a priority;

No money and/or staff and/or time; and

No defined accountability.

Since the primary business goal is financial savings, managers must

understand the principle of economics and run their department as if it were their

own business. In doing so, improving energy efficiency should get proper attention.

This will require some education. Even if the financial gains from energy efficiency

improvements were to seem modest compared to the value of sales or to the overall

budget, they can contribute considerably to the foundrys net profit.

4.6 ENERGY EFFICIENCYThe energy efficiency of the melting process is calculated by dividing the

amount of theoretical energy needed to melt a metal and raise it to its pouring

temperature by the actual amount of energy consumed in melting, treating, holding

and handling the material.

4.6.1 Energy Savings in Induction Furnaces The heat cycle that is pouring to pouring, recorded about 25-40% of the specified

standard time.


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The power to the furnace was varied very frequently due to empty space in thecrucible, excess charge, and sample analysis delay.

The recorded electrical parameters indicate that about 35-40% of the heat timethe furnace was operated at 70-80% of rated power.

About 80% metal is charged before taking the sample for the analysis. Theremaining 20% of crucible volume is loaded after obtaining the sample analysis.

The first batch sample analysis indicates the short fall of different elements,based on this the additional material is added to achieve the required composition

and quantity.

Furnace # 1 Furnace # 2 Furnace Total

Possible reduction in time (min) 6 8 -

Reduction in energy (kW) 24 23.4 47.4

Operating days per year 330 330 -

Operating hours per day 22 17 -

Energy savings (Lakh

kWh/year)

1.95 1.33 3.88

Annual cost savings (Rs. Lakh) 6.30 4.06 10.36

Investment required (Rs. Lakh) 1 1 2

Payback period (Months) 2 3 2

Table 4.06: Details of Saving


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4.6.2 Energy Savings in the Compressed Air SystemThe relation between inlet temperature and relative air delivery and due to

that power consumption can be analysed and it can be seen that lower inlet

temperature can save more power.

Foundry had found inlet temperature about 45C. So from table it consumes morepower. While extending the air intake from the outside of the building, minimize

excess pressure drop in the suction line by selecting a duct of large diameter with

the smallest number of bends that gave air at 32C temperature.

Locate the compressor away from heat sources such as kilns, dryers and otheritems of equipment that radiate heat.

Inlet Temperature (C) Relative Air Delivery

(%)

Power Saved (%)

10.0 102.0 + 1.4

15.5 100.0 Nil

21.1 98.1 1.3

26.6 96.3 2.5

32.2 94.1 4.0

37.7 92.8 5.0

43.3 91.2 5.8

Table 4.07: Effect of intake air temperature on power consumption

4.6.3 Proposed energy Savings in the Electrical Distribution System Stagger the non-critical load according to the electricity tariff to reduce the

energy bill. The benefits of load staggering are shown in Table 8.

Maintain a high power factor, which will lead to reduced demand, better voltage,high system efficiency as well as rebates from the electricity supplying company.

The power factor can be improved by installing capacitors in the electrical


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system. Table shows the benefits of power factor improvements from the point

of view of costs.

Control the maximum demand by tripping non-critical loads through a demandcontroller. This will avoid the penalty levied when usage is greater than the

sanctioned load.

Balance the system voltage to reduce the distribution losses in the system. Forevery 1% increase in voltage imbalance, the efficiency of the motors decreases

by 1%.

Load to be shifted to night shift (10 PM - 6 AM) 15 kW

Assumed working hours per shift 8 hours

Monthly power consumption (30 days/month) 3000 kWh

Electrical cost for night shift operations

( assuming Rs 3.5/kWh during 10 PM - 6 AM)

Rs 1,0500

Electrical cost for general shift operations (assuming Rs.

5/kWh)

Rs 1,5000

Savings per month Rs 4500

Annual savings Rs 54,000

Table 4.08:Benefits of load staggering


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CHAPTER 5

FINDINGS


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From the collected data it is found that the major energy consumption department is

melting department and to save energy from that must carried to save energy from furnaces.

As shown from power distribution tree that accordingly air compressors and electrical

distribution systems are also found major energy consumption areas in foundry after

furnaces. Savings in each department can be accomplished as per choosing best energy

management procedure.

For proper energy management system it would be necessary to choose an efficient

furnace that must be satisfy demand of foundry. Although high energy expenses are a

significant concern for metal casters, many foundries are using melting technologies with

poor energy efficiency. The amount of heat put into the furnace, the thermal efficiency refers

to the percentage of that heat that actually melts the metal. The remaining heat is lost,

through for example, inefficient combustion, the furnaces housing and flue

Supply of the full power during the melting (most of the time) is being practiced.

To lower the specific energy consumption, Reduction in time taken for sampleanalysis & communication was significantly reduced the heat time. Use of intercoms

and alarms, pneumatic conveying and advanced logistical preparations helped to

reduce the time for sample analysis.

In addition to above, use of recently introduced energy optimizer for meltingoperation created a benchmark and enforced conscious practice to complete the job

within the set goal. This energy optimizer senses the inverter output power and

integrates into energy delivered to the furnace. It is possible to set a predetermined

energy requirement value for melting the material to the desired temperature.

For proper energy management, Setting of energy parameter was based on lowestachieved energy consumption figure during the past fortnight. Close monitoring of

set goal and analysis of the reasons for not being able to comply with the

benchmarking if any, shall ensure reaching the optimum level of energy

consumption.


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CHAPTER 6

CONCLUSIONS


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There is a large scope of energy management in foundry industry sector in Indian

small and medium scale foundry industries considering the fact that the large amount of

power is being wasted by many ways. As majority of these foundries are not aware of

these facts.

From above we conclude that the better energy management program may save not

only in terms of energy but also it may save money. Savings of at least 10% and up to

40 % may be realized by implementing some useful energy management techniques.

The key to achieving savings is to take a strategic approach to managing energy use and

giving importance to energy management techniques. While energy efficient

technologies have a significant role to play in reducing energy use in foundry industry.

Most of the small-scale foundry units are family owned and managed. The general

level of awareness among them about energy conservation and new technologies is low.

Although some of the entrepreneurs are interested in energy efficiency and technological

improvements they are constrained by lack of technical know-how and finances.

Looking into todays scenario, it becomes very essential for Foundry men to look for

means which can bring down the energy consumption in melting operation significantly

by efficient methods and techniques

Success of Energy management depends on a team effort starting with a firm

commitment from the top executive and management team. The first assignment in

energy saving activity must be the initial energy audit. It is a key step that establishes

the baseline from which the future energy efficiency improvements can be measured.

One of the main results of energy audit is the possibility of determination of the energy

consumption pattern. The energy pattern is the key in understanding the way energy is

used in a foundry and helps to control energy cost by identifying areas where waste can

occur and where scope for improvement may be possible.

The best available energy management techniques needs to be used in order to

optimise the production. It is expected that there will be ample scope for Indian foundry

operators in energy management


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CHAPTER 7

RECOMMENDATIONS


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This would break new ground in energy-efficiency studies of the foundry industry;

it would produce the first process-oriented energy consumption database that considers

more than just melting energy; and it would generate Energy balances describing

foundry-process energy consumption that reflects the current state of the foundry

industry.

Specifically, the recommended survey project would

Survey all foundries with a written questionnaire. Conduct in-depth energy audits and energy analyses at six to eight foundries. Assimilate and analyse survey and audit data to develop a process-level energy

balance for foundry energy consumption.

Develop a utility tool that field representatives could use to conduct foundrycustomer energy-efficiency analyses at the process end-use level.

If appropriate, determine the energy use that goes into each process step bymonitoring actual energy input and material throughput as part of the energy audits.

Develop a baseline from which foundry utilities can offer a service to quantifyfoundry customer energy consumption as compared to the baseline.

Involve utilities in the study so they can follow-up with specific performanceoptimization proposals. The proposals could lead to case-study examples of foundry

efficiency improvements with before and after results.


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BIBLIOGRAPHY


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1 Barney L. Cape Hart, Wayne C. Turner and William J. Kennedy, Guide to energymanagement.

2 Energy conservation measures in the Foundry sector, Published by: WinrockInternational India, 2010.

3 Chapman, L. R. and Stark, R. 1990. How to Organize an Energy ManagementEffort. Iron and Steel Engineer.

4 Cluster Profile Report Kolhapur Foundry Industry.5 Manufacturing Energy Consumption Survey, Office of Industrial Technology,

Department of Energy, 1998.

Website:

1 Foundry informatics centre. (http://www.foundryinfo-india.org).2 The institute of Indian foundry men (http://www.indianfoundry.org.).3 www.soundcasting.com.4 http://www.energymanagertraining.com/Journal/latesttrend%20greenbusinessc

entre.pdf.
http://www.foundryinfo-india.org/http://www.indianfoundry.org/http://www.indianfoundry.org/http://www.foundryinfo-india.org/

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