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D.DINESH Final Year DME(Foundry) Department of Foundry Technology PSG Polytechnic College
D.DHANYA PRASAD Final Year DME(Foundry) Department of Foundry Technology PSG Polytechnic College
Mr.S.SIVASUBRAMANIAM Lecturer Department of Foundry Technology PSG Polytechnic College Coimbatore 641 004
s.sivasubramaniam@gmail.com
The Indian metal casting industries is a well established sector globally and also has upgraded its position in the rank of tonnage of production of castings in the world. According to the recent world census of castings India ranks as 2nd largest casting producer producing around 7.44 Million MT of various grades of castings as per International standards. It is also known that the Indian foundry industry is growing at the rate of 8-9% per year as the growth of Indias industrial infrastructure is rapid. Currently there are about 4500 foundry units in which about 80% can be bought under the category of small scale industries and 10% each as medium and large scale units. Approx there are about 500 units that are having International Quality Accreditation. The large foundries are competitive globally and are working at nearly full capacity. In India the foundry sector is one of the largest sector that employs around 1, 00,000 people directly and around 1, 50,000 people indirectly. One of the worst features of this foundry sector development is the heavy pall of the green house gases that is emitting from industries that overlay in the surrounding area. The emission contains suspended particulate matter, CO2, Oxides of sulphur etcwhich are tremendous adverse impacts on the human health, vegetation and property. Globally the steps developed to eradicate these green house gas emission is only by stop using of fossil fuels instead using of green terminated resources like solar and wind. But the foundry without the usage of fossil fuels and heat is unimaginable. The possible ways in controlling the green house gas emission form foundries is implementation of advanced manufacturing process with low pollution technology. There are many advanced process even though introduced but does not suit the small scale industries which contribute around 80% of the Indian foundry sector. Different studies were carried out in the small scale industries in and around Coimbatore based on the range of specific fuel consumption and the benchmarking CO2 emissions where compared to the emission from those industries and control process have been made by using following instruments like enhanced operation and maintenance, adoption of environmental friendly systems and by fuel switching in those foundries and its various results have been briefly discussed in this paper that helps the foundry industries for controlling the emissions and also contribute the cyclic growth.
Introduction:
The foundry sector is globally termed as the Mother of all other industrial sector which is practised worldwide. A foundry is a factory that produces metal castings. Metals are cast into shapes by melting them into a liquid, pouring the metal in a mold, and removing the mold material or casting after the metal has solidified as it cools. This sector in global is considered as one of the most developing sector as the need for the castings is developing day by day. In world there are about 1million small, medium and large scale foundries producing about 80,343,064 metric tons of casting produced every year. The following are the top ten countries in casting production.
Rank 1 2 3 4 5 6 7 8 9 10 Country Name China India USA Japan Russia Germany Brazil Korea France Italy Production Rate 35.3million tons 7.4 million tons 7.3 million tons 4.4 million tons 4.2 million tons 3.9 million tons 2.3 million tons 2.1 million tons 1.74 million tons 1.67 million tons
Bureau of Energy Efficiency have listed the top ten major industries that lies behind the emission of GHG in that foundry industry capture one of the major spot in green house gas emissions. One of the main problems that prevail in the foundry sector development is the heavy pall of the green house gases that is emitting from industries that overlay in the surrounding area. The emission contains suspended particulate matter, CO2, Oxides of sulphur etcwhich are tremendous adverse impacts on the human health, vegetation and property. Globally the steps developed to eradicate these green house gas emission is only by stop using of fossil fuels instead using of green terminated resources like solar, wind etc...
Fig: 1
Production (%)
12 9
70
Fig: 2
Automobiles & Auto Components Railways Power Sector Tractor Industry Earth Moving Machinery Pumps, Compressors, Pipes Valves & Pipe Fittings Electrical/Textile/Cement/Agro Machinery Machine Tools & Engineering Industries Sanitary Castings Engineering Exports
The following are the sector wise consumption of castings in percentage as on April 2011
Fig: 3
S.No
1 2 3 4 5 6
Sections
Melting Moulding & Core making Sand preparation Lighting Machining Other
Energy Consumption
70% 10% 6% 5% 5% 4%
S.No
1 2 3 4
Description
Yearly Production( tonnes) Yearly kWh Production (tonnes)/ month Power Consumption kWh/ month
Foundry-A
1224 14,15,332 102 117944.4
Foundry-B
450 7,92,924 37.5 66077
The steel foundries in India produce 880,000 metric tonnes of components every year which contributes about 12% of the Indias total production. The steel foundries in India also contribute about 20% of the total green house gases that is emitted. A case study has been carried out in
two steel foundries and the total gas emission is detailed below. In our case study we have considered mainly on the CO2 emission as they play a major role in global warming and ozone depletion.
Total amount of power consumed Specific Energy Consumption (SEC) = --------------------------------------------------Total amount of casting produced
Description
Specific Energy Consumption (kWh / tonne)
Foundry A
1156.317
Foundry B
1762.053
Description
Annual CO2 emission Specific CO2 emission per ton of casting Average Specific CO2 emission per ton of casting Indias annual production Indias total CO2 emission in the sector.
Foundry A
1259.645 1.03 1.295
Foundry B
705.702 1.56
The CO2 emission in the Indias foundry sector is inside the benchmark standard but not to the minimum required level. Benchmark: 0.46-1.90 kg CO2 / kg
1. Enhanced operations and maintenance 2. Adoption of environmental friendly systems 3. Fuel switching
The following are some of the recommendations that would bring up an eco-friendly foundry: Installation of waste recovery and dust extraction systems. Usage of medium frequency furnaces. Replacement of conventional cupola with cokeless cupola (general). Usage of high efficiency induction motors. Replacement of electrical machining centres with pneumatic machines. Usage of shredded scraps in the furnaces. Usage of eco-friendly lighting systems.
Conclusions:
The GHG mitigation study clearly shows that 60-70% of the GHG emissions are from the electrical usage and other 30-40% from the fuel and improper O&M. It s also came to know that 20-25% of CO2 is emitted from the steel foundries. By following the above instruments and its recommendations the above said adverse effect can be seen in the foundries and also can reduce the GHG emission and can make foundry and its surroundings a better place to work and live in.
References:
1. AIT (2005), Green house mitigation in small and medium scale Industries of AsiaFoundry Sector, Asian Institute of Technology, Thailand. ISBN 97 8208 59 1. 2. Metal world (Feb 2011), Indian Foundry Sector. 3. Modern Casting (Dec 2010), 44th Census of world Casting production. 4. Dr.M.Arasu and L. Roggers Jeffrey, Energy consumption in Foundries, 58th Indian Foundry Congress (2010).