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Energy Efficiency and Cost Saving

Energy costs typically account for 5-7% of the overall operating costs in a metal casting foundry. Energy waste is found in all plants, and improving energy efficiency goes right to the bottom line. Following the procedures outlined in this guide will reduce your energy costs (and dollars spent) per ton

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Yield improvement and defect reduction in

Mar 16, 2004  This will result in considerable business benefits to steel foundries, primarily due to reduced energy and labor costs, increased capacity and productivity, reduced lead-time, and wider use and application of steel castings. As estimated using energy data provided by the DOE, the technology produced as a result of this project will result in an ...

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Metal Casting--Industry of the Future

amount of metal that must be melted, in turn saving energy. Melting efficiency—Melting represents 55% of process energy costs. Improving melting efficiency saves energy and reduces production costs. Environmental benefits—Improving energy efficiency in casting reduces emissions and helps protect the environment. Benefits to local ...

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Castings - ZOLLERN

Castings are made for sculptures, for example, that meet very specific quality requirements. Controlled solidification during the casting process creates almost pore-free surfaces under the casting skin. The model-free production using moulding material milling increases the economic efficiency of

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Energy Saving Melting and Revert Reduction

May 21, 2021  Steel foundries melt recycled scrap in electric furnaces and typically consume 35-100% excess energy from the theoretical energy requirement required to pour metal castings. This excess melting energy is multiplied by yield losses during casting and finishing operations resulting in the embodied energy in a cast product typically being three to six times the theoretical energy requirement.

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ITP Metal Casting: Implementation of Metal Casting Best ...

casting facilities.9 • Save Energy Now: an initiative that helps industrial plants find effective ways to reduce energy use in steam and process heating systems so they can operate more efficiently and profitably, and to identify energy-saving opportunities for

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Yield improvement and defect reduction in steel casting ...

Mar 16, 2004  This will result in considerable business benefits to steel foundries, primarily due to reduced energy and labor costs, increased capacity and productivity, reduced lead-time, and wider use and application of steel castings. As estimated using energy data provided by the DOE, the technology produced as a result of this project will result in an ...

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Advanced Melting Technologies: echnologies - Energy

The energy efficiency of any 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

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The StrikoMelter Plus+ Energy Saving Furnace - StrikoWestofen

It’s 20-year lifespan and global reputation for achieving a near 100% metal yield – all while consuming just 600 kWh/t – has made StrikoMelter Plus+ the industry standard for melting aluminium. Over 95% of the total cost of furnace ownership is generated by energy consumption and loss of metal. The unrivalled durability, efficiency and ...

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BENCHMARKING ENERGY INTENSITY IN STEEL INDUSTRY

employs about 35 000 workers. Energy efficiency is a priority for the CSPA, and Canadian steel producers have reduced specific energy consumption (megajoules [MJ] per tonne of steel shipped) by 23 percent since 1990.1 In 2002, the CSPA agreed to undertake an energy benchmarking study with funding provided by the Industrial Programs Division of

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Steel Foundry Practices and Performance Benchmarking

SFSA solicited energy used plant-wide to produce a ton of shipped steel castings. As can be seen in Table 7, induction melting shops use more electricity and gas to produce a ton of castings. One would expect this, since the batch size is smaller and the energy efficiency is related to

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Foundry sands for use in manufacturing, CDE Global

Typically, around 1 tonne of foundry sand is required for each tonne of iron or steel casting produced. Recycling foundry sand. The recycling of non-hazardous, spent foundry sand can save energy, reduce the need to mine virgin materials and may reduce costs

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(PDF) Energy-Efficient Melting Technologies in Foundry ...

Energy costs typically account for 5-7% of the overall operating costs in a metal casting foundry. Energy waste is found in all plants, and improving energy efficiency goes right to the bottom line.

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Iron and Steel Foundry Castings and Forged Parts

Foundry Castings. Wheelabrator produces an extensive range of blast machines for the Foundry industry. Machines can be "in-line" to treat the castings as they pass through your production processes in a continuous fashion, or "batch" to treat castings in batch quantities. The Wheelabrator range of shot blast machines for foundries includes four ...

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Induction Furnaces for Steel Alloy Melting - Inductotherm ...

These include melting steel scrap to produce a variety of steels and steel castings. Inductotherm offers equipment to make stainless steel, alloy steels and master alloys for the casting industry and various applications including billet, shot, powder, castings and other specialty applications.

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PUREFFICIENCY°: Energy Efficient Furnace - StrikoWestofen

We reduced consumption by up to 10% to a new low of just 489 kWh/t – making PUREFFICIENCY° the most energy efficient aluminium melting furnace out there. The modifications made, together with StrikoMelter’s proven shaft geometry, also make a metal yield of almost 100% possible. With energy consumption and metal loss two of the biggest cost ...

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stainless steel casting lost wax castinglost wax casting ...

High precision casting tolerance. Casting tolerance grade is VDG P690 D1 class which means small maching allowance or no maching. Good Casting surface; the casting surface can be Ra 1.6-3.2um. It suit for many kinds of material and difficult parts, such as stainless steel, carbon steel alloy steel.

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Foundry Process Videos and Animations - StrikoWestofen

StrikoWestofen at Euroguss 2018 - Smart Foundry. Self-optimising, automated, safe and clean: that’s how we see the foundry of the future. We presented this vision at Euroguss 2018 in Nuremberg, Germany, from 16 to 18 January. Innovations as well as proven technologies for light metal foundries could be found at StrikoWestofen booth.

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Norican's Complete Aluminium Foundry

1. Section 1 - Melting and dosing. Eliminating energy and metal waste: optimised furnace efficiency. Melting aluminium is extremely energy intensive. The melt-shop alone can account for as much as 77% of the overall energy consumption in a die casting foundry. It is also a process prone to metal loss.

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Metal Casting--Industry of the Future

amount of metal that must be melted, in turn saving energy. Melting efficiency—Melting represents 55% of process energy costs. Improving melting efficiency saves energy and reduces production costs. Environmental benefits—Improving energy efficiency in casting reduces emissions and helps protect the environment. Benefits to local ...

get price

BENCHMARKING ENERGY INTENSITY IN STEEL INDUSTRY

employs about 35 000 workers. Energy efficiency is a priority for the CSPA, and Canadian steel producers have reduced specific energy consumption (megajoules [MJ] per tonne of steel shipped) by 23 percent since 1990.1 In 2002, the CSPA agreed to undertake an energy benchmarking study with funding provided by the Industrial Programs Division of

get price

Energy-Saving Technology And Measures For Domestic Foundry ...

Steel Casting Piping Pumps manufacturer, supplier in China,Casting industry is a large energy consuming industry, which is restricted by high energy consumption, low energy efficiency, serious pollution and poor economic benefits. It is an important task for foundry industry to use energy rationally

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Iron and Steel Foundry Castings and Forged Parts

Foundry Castings. Wheelabrator produces an extensive range of blast machines for the Foundry industry. Machines can be "in-line" to treat the castings as they pass through your production processes in a continuous fashion, or "batch" to treat castings in batch quantities. The Wheelabrator range of shot blast machines for foundries includes four ...

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Different Types of Casting Process - Steel Casting Foundry

May 13, 2021  The production efficiency is high, and the die-casting mold is used many times; ... The advantages of the high utilization rate of liquid metal, simplified process, and stable quality, etc., are energy-saving metal forming technology with potential application prospects. ... Our steel casting foundry services include stainless steel casting ...

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Foundry sands for use in manufacturing, CDE Global

Typically, around 1 tonne of foundry sand is required for each tonne of iron or steel casting produced. Recycling foundry sand. The recycling of non-hazardous, spent foundry sand can save energy, reduce the need to mine virgin materials and may reduce costs

get price

The Current State of Casting Yield: Results from the 1997 ...

The results of a casting yield survey of steel foundries taken in the first quarter of 1997 are presented. Data collected in the survey includes the average, best case, and worst case castings yields for steel castings, and statistical data on the factors which influence casting yield.

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Articles About Induction Technologies - Inductotherm Corp.

Energy Efficiency System Enhancements in the Induction Melt Shop Author(s): Joseph T. Belsh Publication: Foundry Management Technology Magazine Date: April 2011: An article focusing on how energy heat recovery is used to improve overall efficiency by using the water heat of the water system to provide heat in the foundry during the winter months.

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How much is your melt correction process costing you?

Oct 28, 2020  You might be surprised to learn that a small steel cast foundry with a single 1-ton capacity induction furnace can save over 20,000€ per year, taking into consideration energy and labor costs alone. And the time saved will be enough to run an additional batch, making the financial picture even more attractive.

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Tough as Steel - Industry Today

Apr 26, 2001  Southwest Steel Casting Company is a custom job-shop foundry dedicated to providing a quality product as efficiently and economically as possible. Serving the energy, construction, transportation, marine and mining industries, the company was founded by Ross Williams in 1971. It was purchased by Texas Steel as a supplier to Caterpillar in 1974 ...

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Processes foundry-planet - B2B Portal

From melting to X-rayed parts, Kurtz can supply the complete foundry. Highly efficient low pressure casting technology ensures maximum efficiency and great profits for its customers. Customers include OEM´s as well as TIER´s that are globally present and expect benchmark technology delivered around the

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Digital Solutions and Die Casting Innovation Italpresse Gauss

Digital Solutions and Die Casting Innovation. Unlock Industry 4.0 possibilities. From a powerful, next-generation control system for our high-end die casting equipment to augmented reality app and energy saving solutions. We are constantly developing new technologies that provide you with innovative answers to your production challenges.

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DISAMATIC 240-280 Casting Machinery - DISA Group

Flexible and efficient large casting production with high speed, high volume and high quality. For foundries that are still producing larger castings, such as engine blocks, pipe fittings, fire hydrants, large pumps and manhole covers, on big flask lines, the DISAMATIC 240-280 range offers the opportunity to step up productivity and casting quality and make large moulds faster than ever before.

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Sustainability, Foundry Equipment Manufacturers - DISA Group

For us, a sustainable casting process cuts out different types of waste by being energy-efficient, minimising scrap and finishing work, and enabling greater casting precision. But it also creates a modern, clean, ergonomic and rewarding working environment. These various aspects reflect sustainability’s broad environmental, commercial and social dimensions – and all of them are about a ...

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