Energy Efficiency and Cost Saving Opportunities for Metal Casting An ENERGY STAR® Guide for Energy & Plant Managers January 2016 Document Number 430-R-16-001 Office of Air Programs—Climate Protection Partnership Division Energy Efficiency and Cost Saving Opportunities for Metal Casting An ENERGY STAR® Guide for Energy and Plant Managers Katerina Kermeli, Utrecht University Richard Deuchler, Utrecht University Ernst Worrell, Utrecht University Eric Masanet, Northwestern University January 2016 Disclaimer This guide was prepared for the United States Government and is believed to contain correct information. Neither the United States Government nor any agency thereof, nor any persons or organizations involved in its development, makes any warranty, express or implied, or assumes any legal responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe on privately owned rights. Reference herein to any specific commercial product, process, or service by its trade name, trademark, manufacturer, or otherwise, does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof, or any persons or organizations involved in its development. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof. Development of this guide was funded by the U.S. Environmental Protection Agency. The research embodied in this report was initially supported by the U.S. Environmental Protection Agency through U.S. Department of Energy Contract No. DE-AC02-05CH11231 and was completed under the U.S. Environmental Protection Contract No. EP-BPA-12-H-0012. The cover photograph was provided by Grede LLC of its St. Cloud casting plant. The ENERGY STAR Metal Casting Guide Table of Contents Overview....................................................................................................................................................... 1 Chapter One: Why Energy Management is Good for Your Business ...................................................... 2 Chapter Two: Where to Look for Energy Savings ..................................................................................... 3 Energy Efficiency Opportunities ............................................................................................................. 5 Chapter Three: Energy Management Programs and Systems ................................................................ 8 Energy Savings Checklist: Energy Management .................................................................................. 8 Chapter Four: Motor Systems ................................................................................................................... 12 Chapter Five: Compressed Air Systems ................................................................................................... 18 Chapter Six: Fan Systems .......................................................................................................................... 27 Chapter Seven: Pump Systems ................................................................................................................. 30 Chapter Eight: Lighting .............................................................................................................................. 37 Chapter Nine: Building HVAC ................................................................................................................... 42 Chapter Ten: Dust Control ......................................................................................................................... 48 Chapter Eleven: Process Chain Level ...................................................................................................... 49 Chapter Twelve: Furnace Operation ........................................................................................................ 54 Chapter Thirteen: General Furnace Measures ........................................................................................ 58 Chapter Fourteen: Cupola Furnaces ......................................................................................................... 64 Chapter Fifteen: Electric Induction Furnaces .......................................................................................... 67 Chapter Sixteen: Electric Arc Furnaces ................................................................................................... 72 Chapter Seventeen: Crucible Furnaces ................................................................................................... 75 Chapter Eighteen: Reverberatory and Stack Furnaces .......................................................................... 77 Chapter Nineteen: Ladles .......................................................................................................................... 81 Chapter Twenty: Improve Casting Yield and Decrease Scrap Generation .......................................... 84 Conclusion: Why Manage Energy? ........................................................................................................... 88 Appendix A: The Metal Casting Industry ................................................................................................ 90 Process Description .............................................................................................................................. 92 Appendix B: Energy Consumption by Foundry Type ................................................................................ 95 Energy Use in U.S Iron Foundries ........................................................................................................ 95 Energy Use in U.S. Steel Foundries ...................................................................................................... 96 Energy Use in U.S. Aluminum Foundries ............................................................................................. 98 Appendix C: Diagram of Process and Non-Process Energy Use in U.S. Foundries in 2006 ............... 100 Appendix D: Standards for NEMA Motors ............................................................................................. 101 The ENERGY STAR Metal Casting Guide Appendix E: Energy Management Program Assessment Matrix ......................................................... 102 Introduction ......................................................................................................................................... 102 How To Use The Assessment Matrix ................................................................................................. 102 Interpreting Your Results .................................................................................................................... 106 Resources and Help ............................................................................................................................ 106 Appendix F: Teaming Up to Save Energy Checklist ............................................................................... 107 Appendix G: Support Programs for Industrial Energy Efficiency Improvement .................................. 109 Tools for Self-Assessment .................................................................................................................. 109 Assessment and Technical Assistance ............................................................................................. 111 Federal, State, Local, and Utility Incentives ..................................................................................... 112 Glossary .................................................................................................................................................... 113 References ............................................................................................................................................... 115 The ENERGY STAR Metal Casting Guide 1 Overview This Guide provides information to identify cost-effective practices and technologies to increase energy efficiency in each of three industrial metal casting segments: iron, steel and aluminum. It focuses on the most important systems, processes, and practices that account for the bulk of energy consumption. The information found in this Guide will help energy and plant managers identify energy reduction opportunities in their facility as well as improve the quality of metal casting operations. For additional information on metal casting and associated processes and their energy consumption, please consult Appendix A of this Guide. 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 ton1 of cast metal while improving your environmental reputation as well as image in the community. This Guide is organized as follows: • Chapter One - the value of energy management in a metal casting facility, • Chapter Two – information on energy costs and energy efficiency opportunities in metal casting, • Chapters Three through Twenty-four - step-by-step best practices to save energy and reduce costs, and, • Appendices – explanation on how energy is used in the industry and in various processes