Energy Requirements for Typical Green Sand Foundry

1
sand-binder mixing
core forming
1.2-3.5 MJ/kg saleable casting
core curing
mold core assembly
scrap preparation
mold pouring, cooling
0.7 MJ/kg
mold making
metal melting
slag, dross removal
sand renewal
shakeout
Melting (MJ/kg) Cupola 6.7 Coke 1.3
Electricity 1.9 Natural Gas 0.1 Oxygen Electric
melting 5.0-5.6 Induction 5.0-6.0 Electric
Arc 6.0-9.2 Reverb Fuel fired melting 2.1-7.9
Crucible 2.9-5.8 Reverb
riser cutoff gate removal
1.2 MJ/kg
cleaning, finishing, coating
QA / shipping
Energy Requirements for Typical Green Sand Foundry
2
sand-binder mixing
core forming
100-300g fossil fuel/kg saleable casting
core curing
mold core assembly
scrap preparation
mold pouring, cooling
60 g/kg
mold making
metal melting
slag, dross removal
sand renewal
shakeout
Melting (g/kg) Cupola 170 Coke 120
Electricity 50 Natural Gas 5 Oxygen Electric
melting 450-500 Induction 450-550 Electric
Arc 550-800 Reverb Fuel fired melting 50-200
Crucible 73-150 Reverb
riser cutoff gate removal
100 g/kg
cleaning, finishing, coating
QA / shipping
Energy Requirements for Typical Green Sand
Foundry By Mass Fuel
3
Fuel Requirements

• Using Williams conversion
• 320 g fossil fuel/kWh electricity
• 40 MJ/kg of nonelectric fuel
• 1 kilogram casting using EAF requires 900 g
  fossil fuel
• 1 kg casting using coke cupola requires 550 g
  fossil fuel
• Disparities caused by efficiency of electricity
  production, size(?)