Energy Saving Manual

Energy Saving Manual

The cost of energy represents a large portion of the overall expense in the process of producing die castings. In many instances, energy use in the die casting industry has been found to be the third highest expense in the operation, right behind materials and labor.

NADCA's newly revised Energy Saving Manual is designed to assist the die caster in establishing a strong, profitable energy management program for his or her organization. The book utilizes information and results obtained from several recent projects and studies performed in the metal casting industries to help the die caster determine efficient methods to utilize and conserve energy and to reduce some of the cost associated with producing die castings

TABLE OF CONTENTS

Introduction	3
Effective Strategic Program for Energy Management	5
Understanding Energy Use	9
How To Read An Energy Bill	9
Sample Utility Bills	11
Energy Use Summary Form	17
Conversion Factors	18
Energy Calculations	19
Power Factor	20
Metering the Operation	23
Energy Audits	27
Why Conduct Audits	27
Types Of Audits	27
Develop Audit Forms	28
Conducting the Audit	28
Reporting Audit Results	28
Process Energy	31
Melting	31
Heat Content	31
Theoretical Energy Use	33
Where Losses Occur	33
Furnace Losses	33
Flue Losses	34
Maximize Melting Efficiency	38
Aluminum Drosses	39
Melting Aluminum	44
Ingot Preheating	52
Best Practices & Emerging Technologies	52
Holding	54
Metal Transfer	55
Bull Ladles	56
Launder Systems	57
Ladle Pre-heaters	57
Die Casting Machines	58
Finishing Equipment	60
Non-Process Energy	63
Appendix A: NADCA Energy Audit Form	71
Appendix B: Energy Spreadsheets & Calculations	79
Appendix C: References	80