Energy efficiency opportunities in the service plants of cast iron foundries in Italy

Abstract

Though in a foundry most of the energy is used in the process plants and particularly in energizing furnaces, service plants require absolutely large amounts of energy, above all as electricity. The most energy-consuming service is compressed air preparation, but large amounts are due to lighting, heating, ventilation and air conditioning, pumps and fans. These energy users are common to most of the industrial branches with different weights both in absolute and relative terms. This article reports on the experience of some energy audits carried out in five Italian cast iron foundries allowing to identify the relative importance of different services in this industrial branch. The analysis is based on real data measured during the audits. Energy saving actions were then conceived, comparing the results of new technologies applied in some factory sectors and the energy usage of the previous equipment.