Download or read book FINAL REPORT written by F. Peters and published by . This book was released on 2005 with total page 75 pages. Available in PDF, EPUB and Kindle. Book excerpt: This project worked to improve the efficiency of the steel casting industry by reducing the variability that occurs because of process and product variation. The project focused on the post shakeout operations since roughly half of the production costs are in this area. These improvements will reduce the amount of variability, making it easier to manage the operation and improve the competitiveness. The reduction in variability will also reduce the need for many rework operations, which will result in a direct reduction of energy usage, particularly by the reduction of repeated heat treatment operations. Further energy savings will be realized from the reduction of scrap and reduced handling. Field studies were conducted at ten steel foundries that represented the U.S. steel casting industry, for a total of over 100 weeks of production observation. These studies quantified the amount of variability, and looked toward determining the source. A focus of the data collected was the grinding operations since this is a major effort in the cleaning room, and it represents the overall casting quality. The grinding was divided into two categories, expected and unexpected. Expected grinding is that in which the location of the effort is known prior to making the casting, such as smoothing parting lines, gates, and riser contacts. Unexpected grinding, which was approximately 80% of the effort, was done to improve the surfaces at weld repair locations, to rectify burnt on sand, and other surface anomalies at random locations. Unexpected grinding represents about 80% of the grinding effort. By quantifying this effort, the project raised awareness within the industry and the industry is continuing to make improvements. The field studies showed that the amount of variation of grinding operations (normalized because of the diverse set of parts studied) was very consistent across the industry. The field studies identified several specific sources that individually contributed to large process variation. This indicates the need for ongoing monitoring of the process and system to quantify the effort being expended. A system to measure the grinding effort was investigated but did not prove to be successful. A weld wire counting system was shown to be very successful in tracking casting quality by monitoring the quantity of weld wire being expended on a per casting basis. Further use of such systems is highly recommended. The field studies showed that the visual inspection process for the casting surface was a potentially large source of process variation. Measurement system analysis studies were conducted at three steel casting producers. The tests measured the consistency of the inspectors in identifying the same surface anomalies. The repeatability (variation of the same operator inspecting the same casting) was found to be relatively consistent across the companies at about 60-70%. However, this is still are very large amount of variation. Reproducibility (variation of different operators inspecting the same casting) was worse, ranging between 20 to 80% at the three locations. This large amount of variation shows that there is a great opportunity for improvement. Falsely identifying anomalies for reworking will cause increased expense and energy consumption. This is particularly true if a weld repair and repeated heat treatment is required. However, not identifying an anomaly could also result in future rework processing, a customer return, or scrap. To help alleviate this problem, casting surface comparator plates were developed and distributed to the industry. These plates are very inexpensive which enables them to be provided to all those involved with casting surface quality, such as operators, inspectors, sales, and management.

Download or read book Reduction in Energy Consumption Variability in Steel Foundry Operations written by and published by . This book was released on 2005 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt: This project worked to improve the efficiency of the steel casting industry by reducing the variability that occurs because of process and product variation. The project focused on the post shakeout operations since roughly half of the production costs are in this area. These improvements will reduce the amount of variability, making it easier to manage the operation and improve the competitiveness. The reduction in variability will also reduce the need for many rework operations, which will result in a direct reduction of energy usage, particularly by the reduction of repeated heat treatment operations. Further energy savings will be realized from the reduction of scrap and reduced handling. Field studies were conducted at ten steel foundries that represented the U.S. steel casting industry, for a total of over 100 weeks of production observation. These studies quantified the amount of variability, and looked toward determining the source. A focus of the data collected was the grinding operations since this is a major effort in the cleaning room, and it represents the overall casting quality. The grinding was divided into two categories, expected and unexpected. Expected grinding is that in which the location of the effort is known prior to making the casting, such as smoothing parting lines, gates, and riser contacts. Unexpected grinding, which was approximately 80% of the effort, was done to improve the surfaces at weld repair locations, to rectify burnt on sand, and other surface anomalies at random locations. Unexpected grinding represents about 80% of the grinding effort. By quantifying this effort, the project raised awareness within the industry and the industry is continuing to make improvements. The field studies showed that the amount of variation of grinding operations (normalized because of the diverse set of parts studied) was very consistent across the industry. The field studies identified several specific sources that individually contributed to large process variation. This indicates the need for ongoing monitoring of the process and system to quantify the effort being expended. A system to measure the grinding effort was investigated but did not prove to be successful. A weld wire counting system was shown to be very successful in tracking casting quality by monitoring the quantity of weld wire being expended on a per casting basis. Further use of such systems is highly recommended. The field studies showed that the visual inspection process for the casting surface was a potentially large source of process variation. Measurement system analysis studies were conducted at three steel casting producers. The tests measured the consistency of the inspectors in identifying the same surface anomalies. The repeatability (variation of the same operator inspecting the same casting) was found to be relatively consistent across the companies at about 60-70%. However, this is still are very large amount of variation. Reproducibility (variation of different operators inspecting the same casting) was worse, ranging between 20 to 80% at the three locations. This large amount of variation shows that there is a great opportunity for improvement. Falsely identifying anomalies for reworking will cause increased expense and energy consumption. This is particularly true if a weld repair and repeated heat treatment is required. However, not identifying an anomaly could also result in future rework processing, a customer return, or scrap. To help alleviate this problem, casting surface comparator plates were developed and distributed to the industry. These plates are very inexpensive which enables them to be provided to all those involved with casting surface quality, such as operators, inspectors, sales, and management.

Download or read book Energy Use in the Steel Industry written by C. J. Cairns and published by . This book was released on 1998 with total page 268 pages. Available in PDF, EPUB and Kindle. Book excerpt:

Download or read book Energy Use in the U S Steel Industry written by and published by . This book was released on 2000 with total page 53 pages. Available in PDF, EPUB and Kindle. Book excerpt: The U.S. steel industry has taken enormous strides over the past decades to reduce its energy consumption; since the end of World War II, the industry has reduced its energy intensity (energy use per shipped ton) by 60 percent. Between 1990 and 1998 alone, intensity has dropped from 20 to 18 million Btu (MBtu) per ton. This figure is projected to decrease to 15 MBtu/ton by 2010 with an asymptotic trend towards 14 MBtu/ton. Domestic shipments are projected to flatten out over the next decade to around 105 million tons which means that total energy consumption will also decrease. Historically, the steel industry has accounted for about 6 percent of U.S. energy consumption. Today, that figure is less than 2 percent and will decrease further to 1.5 percent by 2010. The primary causes for the decrease in energy consumption since WWII are: The use of pellets in the blast furnace and the application of new technology in the ironmaking process to further reduce fuel rates per net ton of hot metal (NTHM); The total replacement of the open hearth process by basic oxygen and electric furnaces; The almost total replacement of ingot casting by continuous casting (which improved yield dramatically and thus reduced the tons of raw steel required per ton of shipments); and The growth of the electric furnace sector of the industry at the expense of hot metal-based processes (which has also stimulated scrap recycling so that about 55 percent of ''new'' steel is now melted from scrap steel). This report focuses on the concept of good practices (i.e., those that are sustainable and can use today's technology). If all the industry could operate on this basis, the additional savings per ton could total 2 MBtu, As further restructuring occurs and the swing from hot metal-based to electric furnace-based production continues, the average consumption will approach the good practice energy per ton. Further savings will accrue through new technology, particularly in the areas of reduced blast furnace fuel rates and reheating efficiency, both of which relate to large tonnages of material.

Download or read book Patterns of Energy Consumption in the United States written by Stanford Research Institute and published by . This book was released on 1972 with total page 240 pages. Available in PDF, EPUB and Kindle. Book excerpt:

Download or read book Present and Future Use of Energy in the Canadian Steel Industry written by Richard Fry and published by The Branch. This book was released on 1993 with total page 786 pages. Available in PDF, EPUB and Kindle. Book excerpt: Comprehensive analysis of present and future steel industry technologies through an extensive review of the current literature and discussions with experts at selected steel companies, research institutes, universities, and equipment developers/suppliers in the United States, Europe, Canada, and Japan. Volume 1 analyzes the potential of the technologies under consideration and describes the Canadian steel industry as it existed in 1989, with some updates for 1990/91, and as it could be in the year 2000 and in 2010, and the implications of the potential changes in technologies. Volume 2 describes, in some detail, those technologies applicable to the year 2000, that is the best technologies in operation industrially anywhere in the world today. Volume 3 describes those technologies applicable to 2010, that is those promising technologies being researched and developed now.

Download or read book Guide to Energy Efficiency Opportunities in Canadian Foundries written by Canadian Industry Program for Energy Conservation and published by Canadian Museum of Civilization/Musee Canadien Des Civilisations. This book was released on 2003 with total page 144 pages. Available in PDF, EPUB and Kindle. Book excerpt:

Download or read book Foundry Products Competitive Conditions in the U S Market Inv 332 460 written by and published by DIANE Publishing. This book was released on with total page 368 pages. Available in PDF, EPUB and Kindle. Book excerpt:

Download or read book ENERGY AND ENVIRONMENTAL MANAGEMENT IN METALLURGICAL INDUSTRIES written by R. C. GUPTA and published by PHI Learning Pvt. Ltd.. This book was released on 2012-12-06 with total page 359 pages. Available in PDF, EPUB and Kindle. Book excerpt: This comprehensive book deals with the environmental aspects of metallurgical industries, including ferrous (iron and steel, DRI units, EAF units, ferroalloys and foundries) and non-ferrous (aluminium, copper, lead and zinc) plants. The text, comprising of eight chapters, discusses fundamental aspects of environment management, various energy sources available on the earth and environment awareness required for sustained economic growth. The book provides a thorough understanding of pollution sources in metallurgical industries and their abatement techniques. It also provides details of energy management in metal industry and enumerates factors for metallurgical plant location and layout. Furthermore, it presents health and safety guidelines for metallurgical professionals. The text concludes with discussion on basic legislations related to environment and labour. This book is primarily designed for undergraduate students of metallurgical engineering. Besides, it will also be useful as a ready reference source to professionals associated with metallurgical industries. KEY FEATURES Coverage of various types of environmental issues such as air emission, toxic effluents, solid waste, thermal discharge, noise and radiation. Analysis of renewable and non-renewable energy sources on the earth with current energy usage pattern and future consumption pattern. Description of various activities in the metallurgical units along with discussion of sources of pollution and abatement techniques. Guidelines for the plant location and layout. Basic information about labour health and safety, environmental legislations, labour laws, ISO 14000, carbon credit, etc.

Download or read book Energy Consumption in Manufacturing written by Conference Board and published by . This book was released on 1974 with total page 700 pages. Available in PDF, EPUB and Kindle. Book excerpt: Monograph on the results of a research project to determine and explain trends in power consumption in six manufacturing industries in the USA - identifies changes in production processes and technology which have affected energy use in the past, and includes projections of technological changes and other changes likely to affect energy use up to 1980. Graphs, references and statistical tables.

Download or read book Separation Technologies for the Industries of the Future written by Panel on Separation Technology for Industrial Reuse and Recycling and published by National Academies Press. This book was released on 1999-01-22 with total page 128 pages. Available in PDF, EPUB and Kindle. Book excerpt: Separation processes—or processes that use physical, chemical, or electrical forces to isolate or concentrate selected constituents of a mixture—are essential to the chemical, petroleum refining, and materials processing industries. In this volume, an expert panel reviews the separation process needs of seven industries and identifies technologies that hold promise for meeting these needs, as well as key technologies that could enable separations. In addition, the book recommends criteria for the selection of separations research projects for the Department of Energy's Office of Industrial Technology.

Download or read book Impact of Energy Shortages on the Iron and Steel Industries written by Booz, Allen & Hamilton and published by . This book was released on 1974 with total page 338 pages. Available in PDF, EPUB and Kindle. Book excerpt:

Download or read book Benefits of Increased Use of Continuous Casting by the U S Steel Industry written by United States. Congress. Office of Technology Assessment and published by . This book was released on 1979 with total page 44 pages. Available in PDF, EPUB and Kindle. Book excerpt:

Download or read book Strategy for Energy Use in the Iron and Steel Industry written by United Nations. Economic Commission for Europe and published by New York : United Nations. This book was released on 1983 with total page 198 pages. Available in PDF, EPUB and Kindle. Book excerpt:

Download or read book Energy Research Abstracts written by and published by . This book was released on 1978 with total page 1190 pages. Available in PDF, EPUB and Kindle. Book excerpt:

Download or read book Energy Use Management written by Rocco Fazzolare and published by . This book was released on 1977 with total page 1048 pages. Available in PDF, EPUB and Kindle. Book excerpt:

Download or read book CASTING TECHNOLOGY AND CAST ALLOYS SECOND EDITION written by CHAKRABARTI, A. K. and published by PHI Learning Pvt. Ltd.. This book was released on 2022-10-01 with total page 334 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book emphasizes the underlying metallurgical principles of casting technology so that the students can develop a sound set of analytical skills helpful in the development of improved casting processes and products. Besides comprehensive coverage of the casting processes and elaborate discussion of properties of cast irons, cast steels, and cast non-ferrous alloys, the book also familiarizes the students with the most recent developments in binder systems, casting practices, solidification processing, metal filtration, metallurgy of cast alloys, alloy design, and energy and environment management. In the new edition, the author has tried to update the subject of Casting Technology and Cast Alloys within usual constraints of producing a students' textbook of convenient volume. The book is primarily designed for degree and diploma students pursuing courses in Metallurgical, Mechanical, and Production Engineering disciplines as well as for candidates studying for Associate Membership Examination (AMIIM, AMIE, and GRAD IIF). It would also benefit M.Tech/M.E. students specializing in foundry technology and allied disciplines. New to the Edition • Coverage of most recent research and industrial trial reports on metal melting, solidification, composite materials, etc. • Elaborate discussion of newer technologies in casting including Indian experience of trials with Cokeless Cupola, Composite Materials, 3-D Printing, etc. • Most recent developments in binder systems, casting practices, solidification processing, metal filtration, metallurgy of cast alloys, alloy design, and energy and environment management. Target Audience • Diploma/B.E./B.Tech. (Metallurgical, Mechanical, Production and Manufacturing Engineering) • M.Tech/M.E. (Foundry Technology and Allied Disciplines) • Professional Foundrymen and Engineers