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Energy consumption measurement and benchmarking analysis of American foundries

Energy consumption measurement and benchmarking analysis of American foundries

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  • Time of issue:2021-08-27
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(Summary description)Themeltingprocessinthefoundryindustryconsumesmostoftheenergy,andthesmoothprogressofotherprocessesalsodependsontheefficiencyofthemeltingoperation.Monitoringtheenergyusageofthesmeltingfurnacecanincreaseoutputandreduceenergyconsumption. TheAmericanFoundryAssociationrecentlycommissionedseveralfoundriestocarryoutanenergy-savingresearchanddevelopmentproject.Theprojectadoptsadvancedsub-meteringmethodsconnectedtothemainenergyconsumptiondevice,andtheenergyconsumptionofthefoundrycanbeobtainedthroughsub-metering.Thisinformationisvaluablebecauseitiseasyforafoundrytounderstandthetotalamountofenergyconsumedpermonth,butwanttodeterminetheenergyusagedataofeachequipmentandthespecificprocessofacertainequipmentorprocess.Thetotalenergycostisdifficult. Smeltingoperationsarethemainareaof​​concernforthisresearch,butotherequipmentalsoconsumesconsiderableenergy.Differentequipmentanddifferenttechnologicalprocesseshavedifferentsub-measurementrequirements.Somefrequentlyusedsub-measurementscanbecollectedeverytwominutes,includingmeasurement:powerconsumptionrate(kW),electricenergyconsumedatdifferenttimes,aircompressorandvacuum,temperature(includingmoltenmetaltemperatureandequipmentexternalsurfacetemperature),Operatingtime,naturalgasconsumptionrateandtotalconsumption,oxygenorothergasconsumptionrateandtotalconsumption,metalliquidproduction(includingpoundweightperbatchandpoundweightperday),etc. Accordingtothespecificcircumstancesofthefoundry,thistypeofinformationcanbecollectedbysub-measurementofenergy-intensiveequipmentfrequentlyusedinthefoundry.Theequipmentthatcanbesub-measuredincludes:furnaces,aircompressors,hydraulicpumps,dustcollectors,heating,ventilationandairconditioningdevices,etc. DuringthestudybytheAmericanFoundryAssociation,themoltenmetaloutputandenergyuseofthesefoundrieschangedgreatly,butnotatthesametime.Duringmostofthemeasurementtimefromdaytomonth,theintervalbetweenthemoltenmetalinthesmeltingfurnace,thesmeltingtimeperpoundofmoltenmetal,andotherbatchmeasurementsallshowedgreatchanges.Inmanycases,employeesandmanagementdonotunderstandthescopeofthesechanges.Withoutdetailed,time-differentiatedmeasurement,themeasurementofproductionsituationmaynotbeobvious,sotherootcauseofmonthlymoltenmetalproductionchangesisoftenunclear. Thestudyemphasizedthevalueofitemizedmeasurementincollectingimportantinformationabouttheoperationofthesmeltingfurnace.Toevaluatetheuseofthesmeltingfurnace,datacanbeobtainedfromtracingthedailypowerleveloftheelectricfurnace.Bymonitoringthetimeofusingdifferentpowergradesineachsmeltingcycleoftheelectricfurnace,andsummarizinginformationsuchasalongerperiodoftime(days,weeksormonths),youcanobtainvaluablein-depthknowledgeandinsightsontheoperationoftheelectricfurnace.Associatingthecycletimeofeachsmeltingprocesswiththeusualpowersettingsprovidesmeaningfuldataonproductionchanges.Forthisstudy,4powerlevelswereselectedascommonsettingsduringthesmeltingoperation,including:poweroff,heatpreservation,mediumpower,andfullpower.Thefollowingproblemswerefoundinthemeasurement:longerthanexpectedholdingtime;inappropriatepowersettingsduring"holding";excessiveuseofhighpowersettings;furnacepowerfailureatabnormaltimes.Suggestedcorrectionsforsomeofthethingsdiscovered,savingmorethanUS$1millioninenergycostsperyearwithoutcapitalinvestment. Inaddition,thisresearchhasalsowrittenaspecialreporttosummarizetheoperatingtimeoftheelectricfurnaceunderanypowerlevel(powerfailure,heatpreservation,mediumpower,fullloadpower)setting,andplotthedispersionthatcanrepresenthundredsofelectricfurnaceoperationcycles.Scatter-gramplottohelpunderstandtheoverallstatisticalchangesintheelectricfurnacesmeltingprocess.Themanagementdepartmentcannowmonitortherelativeefficiencyofthesmeltingoperationinanearreal-timemanner,andcangivewarningswhenabnormalconditionsoccur;itcanalsocreatehourly,daily,weeklyandmonthlysummaryreportstoevaluatetherelativeefficiencyoffurnaceoperationsovertimeVariety.Usingthiskindofmeasurementanddatareport,youcanidentifyunexpectedchanges,andyoucanfurtheranalyzethemeasurementresultsintherelevanttimeperiodtoincreaseoutputandreduceenergyconsumption.Thisautomaticanalysisandreportrepresentsanadvancedformofbenchmarkinganalysis(benchmarking),whichisuniquetothefoundryindustry. Anotheroptionistoconductmanualdatacollectionatthefoundry.Asimplechartthatrecordsthestarttimeofimportantpartsofthecyclecanhelpidentifyproblemsthatareoccurringorprovideabasisforimprovingoperations.Automaticdatacollectioncaninclude:thenaturalgasusagerateoftheburner,theopeningtimeofthefurnacedoorandthecastingtime,etc.Forexample,thesemeasurementscanemphasizedifferentburnerhighandlowflamesettingsbetweensimilarfurnaces.Thedataobtainedfromsimpledrawingworkcanhelpmanagersgraspthechangeoffeedingtimeandhelpoptimizeoperations.  Source:"Casting"201710

Energy consumption measurement and benchmarking analysis of American foundries

(Summary description)Themeltingprocessinthefoundryindustryconsumesmostoftheenergy,andthesmoothprogressofotherprocessesalsodependsontheefficiencyofthemeltingoperation.Monitoringtheenergyusageofthesmeltingfurnacecanincreaseoutputandreduceenergyconsumption. TheAmericanFoundryAssociationrecentlycommissionedseveralfoundriestocarryoutanenergy-savingresearchanddevelopmentproject.Theprojectadoptsadvancedsub-meteringmethodsconnectedtothemainenergyconsumptiondevice,andtheenergyconsumptionofthefoundrycanbeobtainedthroughsub-metering.Thisinformationisvaluablebecauseitiseasyforafoundrytounderstandthetotalamountofenergyconsumedpermonth,butwanttodeterminetheenergyusagedataofeachequipmentandthespecificprocessofacertainequipmentorprocess.Thetotalenergycostisdifficult. Smeltingoperationsarethemainareaof​​concernforthisresearch,butotherequipmentalsoconsumesconsiderableenergy.Differentequipmentanddifferenttechnologicalprocesseshavedifferentsub-measurementrequirements.Somefrequentlyusedsub-measurementscanbecollectedeverytwominutes,includingmeasurement:powerconsumptionrate(kW),electricenergyconsumedatdifferenttimes,aircompressorandvacuum,temperature(includingmoltenmetaltemperatureandequipmentexternalsurfacetemperature),Operatingtime,naturalgasconsumptionrateandtotalconsumption,oxygenorothergasconsumptionrateandtotalconsumption,metalliquidproduction(includingpoundweightperbatchandpoundweightperday),etc. Accordingtothespecificcircumstancesofthefoundry,thistypeofinformationcanbecollectedbysub-measurementofenergy-intensiveequipmentfrequentlyusedinthefoundry.Theequipmentthatcanbesub-measuredincludes:furnaces,aircompressors,hydraulicpumps,dustcollectors,heating,ventilationandairconditioningdevices,etc. DuringthestudybytheAmericanFoundryAssociation,themoltenmetaloutputandenergyuseofthesefoundrieschangedgreatly,butnotatthesametime.Duringmostofthemeasurementtimefromdaytomonth,theintervalbetweenthemoltenmetalinthesmeltingfurnace,thesmeltingtimeperpoundofmoltenmetal,andotherbatchmeasurementsallshowedgreatchanges.Inmanycases,employeesandmanagementdonotunderstandthescopeofthesechanges.Withoutdetailed,time-differentiatedmeasurement,themeasurementofproductionsituationmaynotbeobvious,sotherootcauseofmonthlymoltenmetalproductionchangesisoftenunclear. Thestudyemphasizedthevalueofitemizedmeasurementincollectingimportantinformationabouttheoperationofthesmeltingfurnace.Toevaluatetheuseofthesmeltingfurnace,datacanbeobtainedfromtracingthedailypowerleveloftheelectricfurnace.Bymonitoringthetimeofusingdifferentpowergradesineachsmeltingcycleoftheelectricfurnace,andsummarizinginformationsuchasalongerperiodoftime(days,weeksormonths),youcanobtainvaluablein-depthknowledgeandinsightsontheoperationoftheelectricfurnace.Associatingthecycletimeofeachsmeltingprocesswiththeusualpowersettingsprovidesmeaningfuldataonproductionchanges.Forthisstudy,4powerlevelswereselectedascommonsettingsduringthesmeltingoperation,including:poweroff,heatpreservation,mediumpower,andfullpower.Thefollowingproblemswerefoundinthemeasurement:longerthanexpectedholdingtime;inappropriatepowersettingsduring"holding";excessiveuseofhighpowersettings;furnacepowerfailureatabnormaltimes.Suggestedcorrectionsforsomeofthethingsdiscovered,savingmorethanUS$1millioninenergycostsperyearwithoutcapitalinvestment. Inaddition,thisresearchhasalsowrittenaspecialreporttosummarizetheoperatingtimeoftheelectricfurnaceunderanypowerlevel(powerfailure,heatpreservation,mediumpower,fullloadpower)setting,andplotthedispersionthatcanrepresenthundredsofelectricfurnaceoperationcycles.Scatter-gramplottohelpunderstandtheoverallstatisticalchangesintheelectricfurnacesmeltingprocess.Themanagementdepartmentcannowmonitortherelativeefficiencyofthesmeltingoperationinanearreal-timemanner,andcangivewarningswhenabnormalconditionsoccur;itcanalsocreatehourly,daily,weeklyandmonthlysummaryreportstoevaluatetherelativeefficiencyoffurnaceoperationsovertimeVariety.Usingthiskindofmeasurementanddatareport,youcanidentifyunexpectedchanges,andyoucanfurtheranalyzethemeasurementresultsintherelevanttimeperiodtoincreaseoutputandreduceenergyconsumption.Thisautomaticanalysisandreportrepresentsanadvancedformofbenchmarkinganalysis(benchmarking),whichisuniquetothefoundryindustry. Anotheroptionistoconductmanualdatacollectionatthefoundry.Asimplechartthatrecordsthestarttimeofimportantpartsofthecyclecanhelpidentifyproblemsthatareoccurringorprovideabasisforimprovingoperations.Automaticdatacollectioncaninclude:thenaturalgasusagerateoftheburner,theopeningtimeofthefurnacedoorandthecastingtime,etc.Forexample,thesemeasurementscanemphasizedifferentburnerhighandlowflamesettingsbetweensimilarfurnaces.Thedataobtainedfromsimpledrawingworkcanhelpmanagersgraspthechangeoffeedingtimeandhelpoptimizeoperations.  Source:"Casting"201710

  • Categories:Trade info
  • Author:
  • Origin:
  • Time of issue:2021-08-27
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Information
The melting process in the foundry industry consumes most of the energy, and the smooth progress of other processes also depends on the efficiency of the melting operation. Monitoring the energy usage of the smelting furnace can increase output and reduce energy consumption.
 
The American Foundry Association recently commissioned several foundries to carry out an energy-saving research and development project. The project adopts advanced sub-metering methods connected to the main energy consumption device, and the energy consumption of the foundry can be obtained through sub-metering. This information is valuable because it is easy for a foundry to understand the total amount of energy consumed per month, but want to determine the energy usage data of each equipment and the specific process of a certain equipment or process. The total energy cost is difficult.
 
Smelting operations are the main area of ​​concern for this research, but other equipment also consumes considerable energy. Different equipment and different technological processes have different sub-measurement requirements. Some frequently used sub-measurements can be collected every two minutes, including measurement: power consumption rate (kW), electric energy consumed at different times, air compressor and vacuum, temperature (including molten metal temperature and equipment external surface temperature) , Operating time, natural gas consumption rate and total consumption, oxygen or other gas consumption rate and total consumption, metal liquid production (including pound weight per batch and pound weight per day), etc.
 
According to the specific circumstances of the foundry, this type of information can be collected by sub-measurement of energy-intensive equipment frequently used in the foundry. The equipment that can be sub-measured includes: furnaces, air compressors, hydraulic pumps, dust collectors, heating, ventilation and air conditioning devices, etc.
 
During the study by the American Foundry Association, the molten metal output and energy use of these foundries changed greatly, but not at the same time. During most of the measurement time from day to month, the interval between the molten metal in the smelting furnace, the smelting time per pound of molten metal, and other batch measurements all showed great changes. In many cases, employees and management do not understand the scope of these changes. Without detailed, time-differentiated measurement, the measurement of production situation may not be obvious, so the root cause of monthly molten metal production changes is often unclear.
 
The study emphasized the value of itemized measurement in collecting important information about the operation of the smelting furnace. To evaluate the use of the smelting furnace, data can be obtained from tracing the daily power level of the electric furnace. By monitoring the time of using different power grades in each smelting cycle of the electric furnace, and summarizing information such as a longer period of time (days, weeks or months), you can obtain valuable in-depth knowledge and insights on the operation of the electric furnace. Associating the cycle time of each smelting process with the usual power settings provides meaningful data on production changes. For this study, 4 power levels were selected as common settings during the smelting operation, including: power off, heat preservation, medium power, and full power. The following problems were found in the measurement: longer than expected holding time; inappropriate power settings during "holding"; excessive use of high power settings; furnace power failure at abnormal times. Suggested corrections for some of the things discovered, saving more than US$1 million in energy costs per year without capital investment.
 
In addition, this research has also written a special report to summarize the operating time of the electric furnace under any power level (power failure, heat preservation, medium power, full load power) setting, and plot the dispersion that can represent hundreds of electric furnace operation cycles. Scatter-gram plot to help understand the overall statistical changes in the electric furnace smelting process. The management department can now monitor the relative efficiency of the smelting operation in a near real-time manner, and can give warnings when abnormal conditions occur; it can also create hourly, daily, weekly and monthly summary reports to evaluate the relative efficiency of furnace operations over time Variety. Using this kind of measurement and data report, you can identify unexpected changes, and you can further analyze the measurement results in the relevant time period to increase output and reduce energy consumption. This automatic analysis and report represents an advanced form of benchmarking analysis (benchmarking), which is unique to the foundry industry.
 
Another option is to conduct manual data collection at the foundry. A simple chart that records the start time of important parts of the cycle can help identify problems that are occurring or provide a basis for improving operations. Automatic data collection can include: the natural gas usage rate of the burner, the opening time of the furnace door and the casting time, etc. For example, these measurements can emphasize different burner high and low flame settings between similar furnaces. The data obtained from simple drawing work can help managers grasp the change of feeding time and help optimize operations.
 
 
Source: "Casting" 201710
 
 
 
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