With the increasingly serious global energy shortage and environmental pollution, energy conservation and consumption reduction have become an important direction for the development of various industries. Casting production process needs to consume a lot of energy and raw materials, therefore, to adopt effective energy saving and consumption reduction technology to improve the economic benefits of enterprises and protect the environment is of great significance. This paper will discuss the technology of energy saving and consumption reduction in casting production.
Casting production process includes many complex process links, such as melting, pouring, cooling, sand, cleaning and so on. In these links, the main energy consumption includes electricity, fuel and cooling water. Among them, the power consumption is mainly used for the operation of smelting, pouring and fans. Fuel consumption mainly includes coke, gas and oil, etc., mainly used for melting and heat preservation process; The cooling water is mainly used to control the mold temperature and ensure the quality of the casting.
In the process of casting production, there is a lot of energy waste, such as no-load operation of equipment, unreasonable process parameters, poor insulation and so on. In addition, the generation of waste and waste products will also cause the waste of energy.
Energy saving and consumption reduction technology
Optimize process design: Reduce energy consumption and improve production efficiency by optimizing process flow and parameters. For example, using efficient melting equipment, optimizing gating system design, improving mold structure and so on.
Equipment upgrade and transformation: the introduction of efficient and energy-saving equipment to replace the old equipment, reduce energy consumption and maintenance costs. For example, the use of energy-saving melting furnace, high-power agitator and so on.
Waste heat recovery and utilization: The waste heat generated in the production process is recovered for other process links or heating, etc., to improve energy utilization efficiency. For example, the waste heat of pouring is used to preheat the mold.
Energy management: Establish an energy management system, monitor and optimize energy use, and find and solve energy waste problems in a timely manner. For example, the implementation of energy metering systems, real-time monitoring and analysis of energy consumption in each link.
Green manufacturing: The use of environmentally friendly materials and green processes to reduce environmental pollution and resource consumption. For example, the use of environmentally friendly paint, recycling waste and so on.
Personnel training and awareness education: strengthen the training of employees’ awareness of energy saving and consumption reduction, improve the level of operation and responsibility. For example, to carry out energy-saving knowledge training, set up energy-saving incentive mechanism.
Enterprises should be combined with their own actual situation, choose the appropriate energy saving and consumption reduction technology for implementation. Here are some implementation suggestions:
Conduct a comprehensive evaluation of the existing production line, find out the links with high energy consumption and serious waste, and formulate corresponding improvement measures.
Give priority to high-efficiency and energy-saving equipment, and replace old and energy-consuming equipment. For equipment that cannot be replaced, technical transformation or optimization of process parameters.
Establish an energy management system, improve the energy management system and monitoring means, and ensure the effective implementation of energy-saving measures.
Strengthen the training and education of employees’ awareness of energy conservation and consumption reduction, and improve their operational level and sense of responsibility.
Periodically evaluate and adjust energy saving measures to ensure the effectiveness and sustainability of measures.
Through the implementation of energy saving and consumption reduction technology, enterprises can reduce energy consumption and waste in the production process of casting, improve energy utilization efficiency and production efficiency, thereby reducing production costs and improving economic benefits. In addition, energy conservation and consumption reduction also help reduce environmental pollution and achieve green manufacturing and sustainable development.
