Green manufacturing in Foundries

ByD.Dinesh

D.Dhanya Prasad(PSG POLYTECHNIC COLLEGE)

GREEN MANUFACTURI

NGIN FOUNDRIES

INTRODUCTION:

Green technology encompasses a large body of concepts whose definition may vary by group or industry. Green technology is broadly defined as “The technology that finds smarter ways to use our finite natural resources, both in manufacturing materials and in the energy resources used to manipulate them”.

Green technology can include energy material and the waste reductions in manufacturing processes, and the use of alternative manufacturing technologies with the least, the least impact in the human health, the earth and its natural resources.

FIRST STEP: The first step for green manufacturing is to greening the

industry.

Many of us believe the idea that simply recycling our region’s available scrap and sand makes us a green industry and we need not go further, but doing such process we can make only a clean industry not a green industry.

To make our company green industry and also the pioneers in green manufacturing a top management support is required to establish it as a priority, right along with all other key matrices such as safety, quality and probability. A management culture needs to be established to foster the goal of being green and sustainable.

STARTING THE PROCESS:

Now it time to keep our profit oriented company aside to make a green and profit oriented company.

In green manufacturing process we should not forget one thing that every area in the foundry operation is a fertile ground for green savings. To make a foundry green the following are some of the processes:

Energy savings.

Core systems.

Pollution control.

ENERGY SAVINGS: In foundry industry the energy savings comes in four section .

Melting.

Sand reclamation.

Machining.

Lab

MELTING: The industry’s major energy is used in the melting section.

DISADVANTAGE ADVANTAGE

Sheared scraps are used in most foundry in which it contains lots of rust and other non metallic particles that consumes more than 1.7-2 times of the energy to melt.

Using of shredded scraps(contains no non-metallic particles) can save Upto 15-20% of the energy that takes to melt.

Using of baghouse heat recovery system many prevent the wastage of heat that is produced in cupola and also in induction furnaces and use it for later uses. The installation charges for this baghouse heat recovery system may take $150.000 and also prevent a loss of about $144.000/year to the industry.

According to nature saving it is equal to 153 cars removed from the road and also about 8 acres of forest preserved.

Bag house recovery system

SAND RECLAMATION:

The most important section in the foundry industry in which 15% of the industries energy is used:

Thermal sand reclaimer


Many of the foundries don’t have a sand reclamation plant and most industries only have a sand reclamation plant that is fully electrically controlled.

Using of thermal sand reclaimer and pneumatic/ mechanical sand reclaimer saves about 3% of the energy used in this section.

MACHINING: Machining is the most important job in the foundry which deals

with customer satisfaction.

High efficiency motor Pneumatic controlled grinder


The motors at present used in bench grinding and other machining tools consumes more electrical energy.

Instead using high efficiency motors and ultra-high efficiency motors can save Upto 2-5% of the operating energy. And also the usage of pneumatic controlled machines also saves electrical energy and cost.

LAB: The lab in foundries does not consume more energy but to make a

foundry green each and every steps are clearly to be noted and done.

CFL Bulbs Advanced spectrometer

DISDAVANTAGE ADVANTAGE

This is the major problem around the world the usage of incandescent bulb and usage of old model electrical testing machines also consume more energy.

Instead usage of CFL light bulbs and replacing old with advanced machines saves about 2% of electrical energy and also by using transparent roofing sheets may also avoid day lighting.

CORE RECLAMATION SYSTEMS:

To make a foundry green manufacturing it mainly concerns with sand reclamation. Most of the sand used in the moulding is reclaimed but the core sand is not reclaimed.

DIADVANTAGE ADVANTAGE

In INDIA most of the foundries don’t use core reclamation techniques which makes them to stay behind as a non green foundry and non green manufacturing foundry.

The installation of the polygon sieve core reclamation plant may save the core sand to be dumped outside and also making a foundry green manufacturing industry.

ENERGY DISTRIBUTION CHART

40%

15%

20%

5%

5%

5%

10%

MeltingSand ReclamationMachiningLabCore MakingPouringKnock Out

POLLUTION CONTROL:

This is the main concept that has to be done to make foundry green and a green manufacturing unit. This involves upgrading the following processes:

Core making.

Moulding.

Melting.

Pouring.

Knock out and Shot blasting

Machining.

CORE MAKING: This is the base section of the foundries and the second step after

energy saving for green manufacturing in foundries.


During making of core lots of sand get spilled down and also wastage of the sand takes place. Due to this the core section in foundries get dirty which fails to make a foundry a non-green manufacturing unit.

By using the automatic core shooting machine the spillage of sand is reduced and also it makes a green environment and a green manufacturing system.

THE AUTOMATIC CORE MAKING MACHINE AND

CORE SHOOTER

MOULDING: In this section, two types of pollution have to be controlled to

make a foundry green manufacturing, they are noise pollution and air pollution.


Many industries only have the squeeze jolting machine which makes more noise during the sand ramming and also many sand get squeezed out of the mould box which creates a polluted environment.

By the replacing the machines with fully automatic machine the noise pollution and the air pollution will be brought under the control. By making the moulding automatic the mould surface and the mould hardness will be increased.

FULLY AUTOMATIC MOULDING MACHINE

MELTING: In this section the pollution depends on the furnaces used.


Many of the small scale foundries in INDIA use cupola type furnace which releases more amount of carbon content in the atmosphere and also usage of rotary furnaces too create more pollution during initial process.

By replacing such type of furnaces with induction furnaces may reduce pollution in foundries and also by using minute dust extraction towers the pollution can brought under control.

HIGH TOWER DUST EXTRACTION

SYSTEM

POURING: The pollution in pouring section is always a huge problem to the

labours.


The pollution is caused when the hot molten metal reacts with the dust particles that are present in the molded sand and also due to manual pouring of the molten metal.

This pollution can be brought under control by the use of auto pourer machine and also by separating the dust particles from the sand that is used and also avoiding the green sand process.

THE AUTO

POURING MACHINE

KNOCK OUT AND SHOT BLASTING:

Every industry in INDIA including small scale industry use a knock out machine and a shot blasting machine.


Even though the foundries have a machine many of the foundries use a knock out machine that don’t have closed cover around them which increases the pollution and an automatic shot blasting machine.

To reduce the pollution in knock out section the only way is to have a knock out machine with closed cover and larger sieve size and in shot blasting an automatic machine reduces the time.

A TUNNEL BASED CLOSED KNOCK OUT

MACHINE

AN AUTOMATIC SHOT BLASTING ROLLER

MACHINE

MACHINING: The main pollution in foundries is noise that makes the workers

strain and also leading to deafness.


During the machining operation the usage of old motors and usage of old machines makes large noise that creates pollution.

This can be brought under control by using pneumatic controlled machines and also by placing sound absorbers near to them.

ADVANTAGES: The pollution can be brought under control.

The yield of the foundry can be increased.

Good and sound castings can be produced due to automatic machines used.

A green industry can be achieved using this techniques.

A good environment which doesn’t harm the nature and living beings can be created.

Energy can be saved to use in future.

DISADVANTAGES: The installation of the machines needs more investment.

Requirement of technically skilled labours are necessary, this may also lead to unemployment of uneducated labours.

The maintenance of the machines are compulsory and it takes more cost.

ANY QUERIES ?..

LET’S REMEMBER:

PLANT TREES & SAVE ENERGY

Green manufacturing in Foundries

Technology

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