Green Manufacturing- PSG COLLEGE OF TECHNOLOGY

8/13/2019 Green Manufacturing- PSG COLLEGE OF TECHNOLOGY

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ByD.Dinesh

D.Dhanya Prasad(PSG POLYTECHNIC COLLEGE)

GREENM NUF CTURING

IN FOUNDRIES


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INTRODUCTION:

Green technology encompasses a large body ofconcepts whose definition may vary by group orindustry. Green technology is broadly defined as Thetechnology that finds smarter ways to use our finitenatural resources, both in manufacturing materialsand in the energy resources used to manipulatethem.

Green technology can include energy material and the

waste reductions in manufacturing processes, and theuse of alternative manufacturing technologies with theleast, the least impact in the human health, the earthand its natural resources.


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FIRST STEP:

The first step for green manufacturing is to greening the

industry.

Many of us believe the idea that simply recycling our regions

available scrap and sand makes us a green industry and we need notgo further, but doing such process we can make only a clean

industry not a green industry.

To make our company green industry and also the pioneers in green

manufacturing a top management support is required to establish itas a priority, right along with all other key matrices such as safety,

quality and probability. A management culture needs to be

established to foster the goal of being green and sustainable.


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STARTING THE

PROCESS:

Now it time to keep our profit oriented company aside to make agreen and profit oriented company.

In green manufacturing process we should not forget one thing that

every area in the foundry operation is a fertile ground for greensavings. To make a foundry green the following are some of the

processes:

Energy savings.

Core systems.

Pollution control.


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ENERGY SAVINGS:

In foundry industry the energy savings comes in four section.

Melting.

Sand reclamation.

Machining.

Lab


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MELTING:

The industrys major energy is used in the melting section.

DISADVANTAGE ADVANTAGE

Sheared scraps are used in most

foundry in which it contains lots of

rust and other non metallic particles

that consumes more than 1.7-2

times of the energy to melt.

Using of shredded scraps(contains

no non-metallic particles) can save

Upto 15-20% of the energy that

takes to melt.


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Using of baghouse heat recovery system many prevent the wastage ofheat that is produced in cupola and also in induction furnaces and use itfor later uses. The installation charges for this baghouse heat recoverysystem may take $150.000 and also prevent a loss of about

$144.000/year to the industry.

According to nature saving it is equal to 153 cars removed from the roadand also about 8 acres of forest preserved.

Bag house recovery system


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SAND

RECLAMATION:

The most important section in the foundry industry in which 15%

of the industries energy is used:

Thermal sand reclaimer


Many of the foundries dont have a

sand reclamation plant and most

industries only have a sand

reclamation plant that is fully

electrically controlled.

Using of thermal sand reclaimer

and pneumatic/ mechanical sand

reclaimer saves about 3% of the

energy used in this section.


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MACHINING:

Machining is the most important job in the foundry which dealswith customer satisfaction.

High efficiency motor Pneumatic controlled grinder


The motors at present used in

bench grinding and other

machining tools consumes more

electrical energy.

Instead using high efficiency

motors and ultra-high efficiency

motors can save Upto 2-5% of the

operating energy. And also the

usage of pneumatic controlled

machines also saves electrical

energy and cost.


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LAB:

The lab in foundries does not consume more energy but to make a

foundry green each and every steps are clearly to be noted and

done.

CFL Bulbs Advanced spectrometer

DISDAVANTAGE ADVANTAGE

This is the major problem around the

world the usage of incandescent bulb and

usage of old model electrical testing

machines also consume more energy.

Instead usage of CFL light bulbs and

replacing old with advanced machines

saves about 2% of electrical energy and

also by using transparent roofing sheets

may also avoid day lighting.


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CORE RECLAMATION

SYSTEMS:

To make a foundry green manufacturing it mainly concerns with

sand reclamation. Most of the sand used in the moulding is

reclaimed but the core sand is not reclaimed.

DIADVANTAGE ADVANTAGE

In INDIA most of the foundries

dont use core reclamation

techniques which makes them to

stay behind as a non green foundry

and non green manufacturing

foundry.

The installation of the polygon sieve

core reclamation plant may save the

core sand to be dumped outside and

also making a foundry green

manufacturing industry.


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ENERGY

DISTRIBUTION CHART

40%

15%

20%

5%

5%

5%

10%

Melting

Sand Reclamation

Machining

Lab

Core Making

PouringKnock Out


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POLLUTION CONTROL:

This is the main concept that has to be done to make foundry green

and a green manufacturing unit. This involves upgrading the

following processes:

Core making.

Moulding.

Melting.

Pouring.

Knock out and Shot blasting

Machining.


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CORE MAKING:

This is the base section of the foundries and the second step after

energy saving for green manufacturing in foundries.


During making of core lots of sand

get spilled down and also wastage of

the sand takes place. Due to this the

core section in foundries get dirty

which fails to make a foundry a

non-green manufacturing unit.

By using the automatic core

shooting machine the spillage of

sand is reduced and also it makes a

green environment and a green

manufacturing system.


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THEAUTOMATICCORE

MAKINGMACHINEANDCORE

SHOOTER


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MOULDING:

In this section, two types of pollution have to be controlled to

make a foundry green manufacturing, they are noise pollution and

air pollution.


Many industries only have the

squeeze jolting machine which

makes more noise during the sand

ramming and also many sand get

squeezed out of the mould box

which creates a pollutedenvironment.

By the replacing the machines with

fully automatic machine the noise

pollution and the air pollution will

be brought under the control. By

making the moulding automatic the

mould surface and the mouldhardness will be increased.


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FULLYAUTOMATIC

MOULDINGMACHINE


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MELTING:

In this section the pollution depends on the furnaces used.


Many of the small scale foundries

in INDIA use cupola type furnace

which releases more amount of

carbon content in the atmosphere

and also usage of rotary furnaces

too create more pollution during

initial process.

By replacing such type of furnaces

with induction furnaces may

reduce pollution in foundries and

also by using minute dust

extraction towers the pollutioncan brought under control.


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HIGHTOWERDUST

EXTRACTIONSYSTEM


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POURING:

The pollution in pouring section is always a huge problem to the

labours.


The pollution is caused when the

hot molten metal reacts with the

dust particles that are present in

the molded sand and also due to

manual pouring of the molten

metal.

This pollution can be brought

under control by the use of auto

pourer machine and also by

separating the dust particles from

the sand that is used and also

avoiding the green sand process.


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THEAUTOPOURING

MACHINE


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KNOCK OUT AND SHOT

BLASTING:

Every industry in INDIA including small scale industry use a knock

out machine and a shot blasting machine.


Even though the foundries have a

machine many of the foundries use

a knock out machine that dont

have closed cover around them

which increases the pollution and an

automatic shot blasting machine.

To reduce the pollution in knock out

section the only way is to have a

knock out machine with closed

cover and larger sieve size and in

shot blasting an automatic machine

reduces the time.


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A TUNNELBASEDCLOSED

KNOCKOUTMACHINE

AN AUTOMATIC SHOT


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ANAUTOMATICSHOT

BLASTINGROLLER

MACHINE


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MACHINING:

The main pollution in foundries is noise that makes the workers

strain and also leading to deafness.


During the machining operation

the usage of old motors and

usage of old machines makes

large noise that creates

pollution.

This can be brought under

control by using pneumatic

controlled machines and also by

placing sound absorbers near to

them.


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ADVANTAGES:

The pollution can be brought under control.

The yield of the foundry can be increased.

Good and sound castings can be produced due to automatic

machines used.

A green industry can be achieved using this techniques.

A good environment which doesnt harm the nature and living

beings can be created.

Energy can be saved to use in future.


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DISADVANTAGES:

The installation of the machines needs more investment.

Requirement of technically skilled labours are necessary, this may

also lead to unemployment of uneducated labours.

The maintenance of the machines are compulsory and it takes

more cost.


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ANYQUERIES?..


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LETS REMEMBER:

PLANT TREES & SAVE ENERGY


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Green Manufacturing- PSG COLLEGE OF TECHNOLOGY

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