Energy audit workbook for die casting plants

Technical Report · Fri Sep 01 04:00:00 EDT 1978

OSTI ID:6539473

In a typical die-casting plant, it is possible to save as much as 15% of utility costs through common-sense actions without any appreciable capital expenditure. The workbook provides a do-it-yourself, fill-in-the-blanks approach to an energy-conservation program for die-casting plants that do not have full-time engineering personnel. Energy-conservation measures that demand no capital investment are: reduce the preheat time for molds and furnaces to the minimum required; preheat charge metal by storing on top of the furnaces; not over-fire; adjust the length of the mold preheater pilot flame to a minimum; lower the thermostats in the office area during the heating season; make the monthly energy consumption and cost data available to the manager and chief operating engineer; turn off stand-by furnaces that aren't absolutely necessary; lower the domestic hot water to 105/sup 0/F; and adjust burners to operate at the best efficiency. Measures that have shown a dramatic savings for the least initial investment are: design dies to minimize the amount of metal in the sprues and gates; cover hot stand-by crucibles with insulating covers; install electric ignitors at casting stations to eliminate the large gas pilot flames; put insulated covers on charging ports to cut down the radiation losses; if practical, use exhaust gas heat to preheat inlet air or to heat hot water; if you use a boiler for space heating, have a technician check the efficiency; use energy conserving fluorescent lamps; control exterior lighting with photo electric cells; preheat combustion air where practical; and if you are being penalized by the electric company for a low power factor, it may be cost-effective to correct it.

• Research Organization: Department of Energy, Washington, DC (USA)
• OSTI ID: 6539473
• Report Number(s): DOE/CS-0041/5
• Country of Publication: United States
• Language: English

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320104 -- Energy Conservation
Consumption
& Utilization-- Commercial & Industrial Buildings-- (-1987)
320303 -- Energy Conservation
Consumption
& Utilization-- Industrial & Agricultural Processes-- Equipment & Processes
ACCOUNTING
AIR CONDITIONING
CASTING
DIES
EFFICIENCY
ELECTRICAL EQUIPMENT
ENERGY ACCOUNTING
ENERGY ANALYSIS
ENERGY CONSERVATION
ENERGY EFFICIENCY
ENERGY MANAGEMENT
EQUIPMENT
FABRICATION
HEATING
INDUSTRIAL PLANTS
LIGHTING SYSTEMS
MAINTENANCE
MANAGEMENT
POWER FACTOR
SPACE HEATING
VENTILATION