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. Smeltingoperationsarethemainareaofconcernforthisresearch,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. Smeltingoperationsarethemainareaofconcernforthisresearch,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:
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- Time of issue:2021-08-27
- Views:0
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