Technical Paper

Resource savings by optimising process conditions in foundries

Niels Skat Tiedje - Department of Manufacturing Engineering
and Management Technical University of Denmark, Christian
Drivsholm and Rudolf Crepaz - Danish Technological Institute,
and Sren Skov-Hansen - Disa Industries A/S
This paper was presented at the 68th World Foundry Congress, held
in Chennai, India in February 2008. It is published with kind permission
of the Institute of Indian Foundrymen and the World Foundrymen
Organization.
Abstract
Foundries are some of the major consumers of resources: power, metals,
water, sand etc. To reduce CO2 emission and save resources it is important
to optimise foundry processes to reduce consumption of energy and raw
materials without reducing productivity.
The paper presents means to reduce energy consumption for melting
and ventilation. It is shown that considerable savings are achievable even in
efficient, modern production plants.
Energy for melting can be reduced by improving yield. This will lead to
reduced consumption of metal, sand, binders and other raw materials in the
foundry. Properly designed gating systems will allow the foundry to lower the
pouring temperature without affecting the quality of castings.
Energy for ventilation can be reduced by optimising shielding around
moulding lines and furnaces and by supplying fresh air correctly.

Introduction
Foundries all over the world are some of the most resource demanding
facilities. Large amounts of energy are used for melting, holding, heat
treatment, ventilation, etc. Other resources such as metals, water, sand,
and organic compounds are also used extensively. These materials are
recycled to the highest possible degree, but in spite of that many resources
are consumed by the foundry industry. It is natural that an industry based on
melting metals consumes a lot of energy and the products supplied by the
industry are in high demand all over the world for a multitude of applications,
therefore foundries play an essential role in maintaining and developing
modern society.
Comprehensive life-cycle assessment projects have been conducted on
Danish manufacturing industries(1,2) . The investigations show that when the
total environmental load in the manufacturing process is considered, cast
products are highly competitive against many other types of manufacturing
processes. Therefore it is important for the foundry industry to stay
competitive against other industries and to strive to minimise the impact on
the global society so that it will at all times be considered an environmentally
responsible industry in the eyes of the public.

Fig. 1.
house casting.
- overview.
Right
- section through
Fig.
1 Valve
: Valve
house Left
casting.
Left,
overview.
Right,casting.
section
through casting.

156

In practice the two first points are the foundry engineers job
while the last point rests with the designer. In a research

The potential for saving energy is very large. In

Denmark, the total amount of energy used for melting
in 2006 was approximately 100 GWh(2,3). In the
casting process it is common that the yield, i.e. the
ratio between the weight of the casting and the total
amount of metal poured in the mould, varies from
40 to 60%. The yield is low because it is necessary
to have a suitable gating system and in some cases
feeders to make high quality castings. But if it is
possible to increase the yield, even by a few percent,
the potential savings in energy consumption directly
related to melting is considerable. If the amount of
returned metal is reduced, it will affect all parts of the
foundry since internal transport of materials will be
reduced. Emissions to the surroundings will also be
reduced leading to a lower need for ventilation and the
amount of waste will thus be reduced.
Globally there is focus on energy and resource
savings in foundries and the methods to achieve
savings(4-7) are many.
The most efficient route to achieve large savings
is to build new foundries with the most modern
technology. Studies have shown that extensive use
of modern technology combined with an efficient
plant lay-out will reduce energy consumption
considerably(4-6,8).
In existing foundries where building a new plant
is not an option, there are still many possibilities for
saving energy. Here well planned and continuous
focus on energy consumption will give savings to the
foundry(5).
This paper will focus on recent work where the
combined efforts by Danish foundries and research
and development institutions have shown roads to
significant energy savings at relatively low investments
in existing foundries.
The projects described here focus on improving
yield by optimising gating systems and by designing
ventilation systems to minimise power consumption
for ventilation. The methods are already successfully
employed in the industry.

Reduction of poured weight

The poured weight in the mould is the sum of the

weight of the casting itself and the weight of the gating
system including feeders. The poured weight can be
reduced by:
Minimising the weight of the gating system
Minimising the weight of feeders
Reducing the weight of the casting
In practice the two first points are the foundry
engineers job while the last point rests with the
designer. In a research project a valve casting was
used as a test case to investigate the extent to which
it is possible to reduce the total poured weight by
focussing on all three points simultaneously(9).
Fig.
2 test
: a.casting
Traditional
lay-out; valve
b. streamlined
The
was a cylindrical
housing in lay-out
ductile cast iron with a central flange that holds the
guidelines
rely on the use of simple geometries for
valve unit, see fig. 1. The casting, as it was designed
sprues
and wells,
anda large
the use
ends to contr
by the customer,
needed
feederofat dead
the central
flange.
Theto
sizeavoid
of the flange
the proximity
of
flow
and
cold and
metal
from entering
the cast
the feeder (fig. 2) meant that local cooling time in

It has been shown that, in modern, efficient productio

melt flow in such gating systems is inherently unstab
has been shown that by designing
sprues, runne
FTJ June 2009
ingates in a stream lined manner so that the melt is c
and guided into the casting and turbulence and splas

Technical Paper

the flange was excessively long and temperature

distribution in the casting was inhomogeneous.
As a result, there was a large variation in the
mechanical properties of the casting in the load
bearing - the critical part of it. This was compensated
for by a subsequent heat treatment.
Based on a simulated load analysis the central
flange was redesigned so that its thickness was
reduced to suit the critical load as defined by the
designer. The result being that it was no longer
necessary to apply a feeder to the flange. The feeder
could now be moved to the top of that casting, and the
Fig.
2 Traditional
: a. Traditional
b. streamlined
lay-out
Fig.
2. (a)
lay-out;lay-out;
(b) streamlined
lay-out
ingate could be moved to the bottom of the casting.
guidelines rely on the use of simple geometries for runners,
Now, temperature gradients in the casting were
sprues and wells, and the use of dead ends to control melt
improved, so that shrinkage was avoided, and the
10

Traditional
Weight
flange was cooled uniformly and sufficiently rapid to
flow
and to avoid cold
metal Streamlined
from enteringWeight
the casting.

layout
layout
reduction
reduction
obtain the necessary mechanical properties without
: Valve house
casting.
overview.
Right, section
It has been shown that, (kg)
in modern,(kg)
efficient production
lines,
(9)
(kg)
(%)
subsequent
heat Left,
treatment
.
11 It
through casting.
melt
flow
in
such
gating
systems
is
inherently
unstable.
The gating system was designed on the basis of
Total poured weight
19.7
15.5
4.2
21
well established rules that are found in the literature.
has been shown that by designing sprues, runners and
Weight ofin
casting
1.0 is confined
5
ctice the two
first
points rely
are on
thethefoundry
engineers
job ingates
These
guidelines
use of simple
geometries
a stream lined9.0
manner so8.0 that the melt
for runners,
and theIn
useaofresearch
dead
the last point
rests sprues
with and
thewells,
designer.
and
guided
into the casting
and
Weight
of feeders
5.0 and turbulence
2.9
2.1 splashing
10 is
ends to control
melt flow
and
to avoid
cold
metal from
9,11
a valve casting
was used
as
a
test
case
to
investigate
reduced.
Weight of gating system
5.6
4.5
1.1
6
casting(10).
ch extent,entering
it is the
possible
to reduce the total poured
It has been shown that, in modern, efficient
In
stream
lined
gating
systems
all
parts
are
designed
by
9
by focussing
on lines,
all three
points
simultaneously.
production
melt flow
in such
gating systems
application
the Bernoulli
and aReduction
mass balance
Table 1: Weightof
of layouts
before and equation
after modification.
in weight to
of
inherently
unstable(11).valve
It has also
been shown
st castingiswas
a cylindrical
housing
in ductile all
casting
and sections
feeder in kgand
and in
of total
weight before
cross
bypercent
strictly
avoiding
all modification
sharp corners
by designing
runners
ingates
in a see
on with a that
central
flange sprues,
that holds
theandvalve
unit,
in the gating system. 12 Ingates are designed by a method
streamlined manner, so that the melt is confined and
The casting,
as it was designed by the customer,
frequently
hightemperature
pressure die
casting
theform
soguided into the casting, turbulence and splashing is
foundry, freshapplied
air at thein
proper
will have
to bewhen
supplied
13 The result becomes a smooth
a large feeder
at
the
central
flange.
The
size
of
the
(9,11)
called
fan
gates
are
used.
reduced
.
the outside. This is often done by blowing fresh, heated or cooled air into
and the proximity
of the
feeder
(Fig.
2) meant
that gating
In streamlined
gating
systems
all parts
are
the foundry.
The amount
of energy
required
operate
moderninventilation
system
through
which
thetomelt
flows
a well
designed
by application
of the
Bernoulli equation
cooling time
in the
flange was
excessively
long and
and
systems is considerable.
There
therefore
also acontrolled
potential forconditions
saving energy
controlled
manner and
is is
guided
under
a mass balance
cross sections
and by strictly
by optimising
ventilation systems. Savings are easily obtained, since the ratio
ature distribution
in theto all
casting
was inhomogeneous.
into
the casting.
(12)
avoiding
all
sharp
corners
in
the
gating
system
.
between
power
consumption for ventilators and air flow is:
result, there was a large variation in the mechanical
The redesigned casting and gating system is shown in
Ingates are designed by a method frequently applied
2.5
ies of the casting in the load bearing, critical part of
V (m3 / h)
in high pressure diecasting when the so-called fan
Fig. 2b.
ENew (kW) = EOld (kW) New 3
s was compensated
for
by
a
subsequent
heat
treatment.
(13)
gates are used . The result becomes a smooth
V (m / h)
Test castings were performed in Oldthe laboratory and in
gating system
which
melt flows
in a well
on a simulated
load through
analysis
thethecentral
flange
was
production
the consumption
foundry that
normally
produce
thevolume
castings.
controlled manner and is guided under controlled
Where E isat
power
to drive
ventilators,
V is the
of
gned so that
its thickness was reduced to suit the
conditions into the casting. The redesigned casting
air
removed
and
index
new
and
old
indicate
conditions
before
and
after
The
laboratory
tests
showed
that
melt
flow
during
filling
was
load as defined
by the designer. The result was that
and gating system is shown in fig. 2b.
modifications are done.
calm
and balanced so that all castings were made under
no longer necessary
apply
a feeder
the flange.
Test castingstowere
performed
in thetolaboratory
and
Ventilation at hot processes such as casting should be designed
so that
equal
conditions and with equal cooling conditions.9
eder couldin production
now be moved
to thethattop
of that
casting,
at the foundry
normally
produces
most fumes are removed at the source. This is normally combined with
the castings.
The laboratory
tests showed
thatcasting.
melt
e ingate could
be moved
to the bottom
of the
background
where fumes
that escape
the local
The
tests ventilation
in the foundry
where
castings
areexhaust
made are
on a
flow
during
filling
was
calm
and
balanced
so
that
removed by amoulding
system, typically
mounted
in the
ceiling
over the porosities
process line.
emperature gradients in the casting were improved,all so Disamatic
line
revealed
that
shrinkage
were made
under
equal
conditions
with
A series of experiments was conducted in the laboratory to optimise the
hrinkage castings
was avoided,
and
the
flange
wasand
cooled
were avoided. The mechanical properties of the castings
equal cooling conditions(9).
balance
between local ventilation and the background ventilation over hot
mly and sufficiently
rapid to obtain the necessary were uniform
lived
up toThese
the costumers
The tests in the foundry, where castings are made9
processes such asand
melting
furnaces.
measurementsrequirements.
were combined
nical properties
without
subsequent
heat that
treatment.
on a Disamatic
moulding
line, revealed
shrinkage
Further,
it
was
found
that
it
was
possible
to reduce
pouring
with measurements in a number of industries using thermal
processes
to
porosities
were
avoided.
The
mechanical
properties
temperature
by
at
least
100
C
without
influencing
the
quality
develop
an
internet
based
calculator
which
can
be
used
to
provide
dimension
ating system was designed on the basis of well
of the castings were uniform and lived up to the
optimised
ventilation systems(14,15).
the castings.
shed rules
that are found in the literature. These of
customers requirements. Further, it was found that
The foundry tested had a Disamatic moulding line where the ventilation
it was possible to reduce pouring temperature by
over the cooling line was a standard combination of ventilation to remove
1 and inlet of fresh air over the moulds to cool and compensate for
at least 100C without influencing the quality of the Tablefumes
castings.
Weight of layouts before and after modification. Reduction
in weight
andthat
feeder
in kgrequirements
and
air removed,
see fig.of
3. Itcasting
was found
ventilation
could be
Table 1 shows the savings in
obtained
for of
thetotal weightreduced
percent
beforefrom
modification.
110 kw to 40 kw and addition of fresh air could be omitted.
complete layout shown in fig. 2. The largest saving
With production in one shift, annual savings will be approximately 120 mwh.
is on the feeders, but also the weight of the gating
In other industries it was found that by simple means such as moving
Traditional
Streamlined
Weight
Weight
system is reduced considerably.
exhaust hoods as close as possible to the source it was possible to reduce

layout

Optimisation of ventilation systems [kg]

In all modern foundries ventilation to remove toxic

al pouredgasses,
weightdust and excess heat is important19.7
to meet

ight of

the requirements for a sound working environment.

casting
9.0
When large amounts of air are removed form the

reduction
power layout
consumption for ventilation
considerably(4-6,8).

[kg]

reduction
[%]

15.5

4.2

21

[kg]

Discussion

By applying the principles of streamlined gating systems to casting layouts

it is possible
8.0 to improve yield of casting
1 .0 processes. It is realistic
5 to expect
that in the order of 5% can be saved on the gating system itself. Further

ight of feeders

5.0

2.9

2.1

10

ight of gating
system
FTJ June
2009

5.6

4.5

1.1

157

Technical Paper
saving may be achieved through optimisation of feeders. The latter savings
will depend very much on casting geometry and on whether insulating or
exothermal feeders are used in the foundry. It is difficult to estimate on
average the amount that can be saved in this way, but it is likely that most
foundries will be able to reduce their costs for melting here too.
Using data for energy consumption in Danish foundries and assuming
that 5% metal is saved, energy consumption for melting alone will be
reduced from 1.194 kwh/kg iron to 1.134 kwh/kg iron. As the total European
production of cast iron was approximately 13 Mt in 2005, the direct savings
for melting alone will be 15 TWh power annually.
By using streamlined gating systems it will also be possible to reduce
the pouring temperature. In the present work it was found that a reduction
of 100C was possible to achieve. This will lead to savings for heating and
holding metals, but it will also reduce wear on refractories, and reduced need
for ventilation so the total savings are achieved in all parts of the foundry.
Further savings are possible if casting design is made specifically to
the process by which parts are to be produced. At present these savings
are more difficult to achieve since it requires close co-operation between
designers and foundrymen. In the future it will be possible to define criteria
in process modelling software so that the software can be used actively in
the process of optimising casting design and feeding and gating to give good
castings at the highest possible yield(16).
Total power consumption for ventilation in the Danish foundry industry
is approximately 40 GWh/year. By optimising design and placement of
ventilation hoods and by proper design of basis ventilation it will be possible
to reduce power consumption by 30 to 50% (approximately 12 to 20 GWh/
year). Energy for ventilation is divided between exhaust and supply of fresh
air in a ratio of 3:1. This means that if, for example, 27 GWh are used for
exhaust, then 9 GWh will be used for supply of fresh air. The fresh air has to
be heated to 18C and the energy required for that is approximately 80 GWh/
year(14).
It is clear, bearing equation 1 in mind, that a reduction in energy
consumption by 40% will give massive power savings in foundries.
Rules and regulations for ventilation differ between countries, but within
Europe and North America there is great potential for saving power if
facilities focus on this. This is an area where improved design criteria and
use of modern modelling tools would be of great help. But these methods still
need to be developed.

Conclusion
Implementation of modern gating systems will improve yield in foundries so
that at minimum a 5% saving in power consumption is possible. In addition,
there will be savings in all parts of the production process. The size of these
savings will depend on foundry infrastructure and equipment, and are difficult
to predict.
Use of modern modelling tools will make it possible to conduct integrated
analysis of feeding and gating design to optimise production further.
Optimisation of the design of ventilation systems will lead to significant
savings in power consumption.

Fig. 3 : Ventilation over Disamatic moulding line.

Table 3.
1 shows
the savings over
obtainedDisamatic
for the completemoulding
lay out
In aline
foundry
Fig.
Ventilation
shown in Fig. 2. The largest saving is on the feeders, but
also the weight of the gating system is reduced considerably.

OPTIMISATION OF VENTILATION SYSTEMS

In all modern foundries ventilation to remove toxic gasses,
dust and excess heat is important to meet the requirements

for a sound working environment. When large amounts of air

158

are removed form the foundry, fresh, air at the proper

temperature will have to be supplied form the outside. This
is often done by blowing fresh, heated or cooled air into the
foundry. The amount of energy required to operate modern

with a Disamatic moulding line where the

ventilation over the cooling line was a standard combination
of ventilation to remove fumes and inlet of fresh air over the
moulds to cool and compensate for air removed, see Fig. 3.
It was found that ventilation requirements could be reduced
from 110 kW to 40 kW and addition of fresh air could be
omitted. With production in one shift, annual savings will be
approximately 120 MWh.
In other industries it was found that by simple means such
a moving exhaust hoods as close as possible to the source
it was possible to reduce power consumption for ventilation
considerably.4-6,8

New, improved guidelines for design and

dimensioning of ventilation systems have been
developed. But there is still a need for further
development of tools to optimise industrial ventilation
systems.

Acknowledgements
The authors wish to thank the Danish power distributor
Energinet.dk for financing the work.

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FTJ June 2009