Guide to Energy Efficiency Opportunities in Canadian Foundries

In Partnership with the Canadian Foundry Association

Introduction

Acknowledgements and disclaimer

Profile of the Canadian foundry industry

Environmental considerations
 

1.0 Setting up an Energy Management Program

• 1.1 How to get started
• 1.2 Auditing energy use in a foundry
  • 1.2.1 Initiating the audit
  • 1.2.2 Preparing the audit
  • 1.2.3 Auditing
  • 1.2.4 Reporting the audit results
• 1.3 Understanding the audit results
• 1.4 Implementing the energy management program
• 1.5 Involving employees

2.0 Getting Ideas for Energy Management Opportunities

• 2.1 General foundry management
  • 2.1.1 Building design and plant layout
  • 2.1.2 Transportation and distribution factors
  • 2.1.3 Design influences
  • 2.1.4 Production scheduling, productivity and process control
  • 2.1.5 Focusing on yield
  • 2.1.6 Scrap and recycling
  • 2.1.7 Considering energy issues in change management
  • 2.1.8 Managing energy as raw material
  • 2.1.9 Maintenance issues
  • 2.1.10 Full cost accounting
  • 2.1.11 Implementing a management system
• 2.2 Utilities management
  • 2.2.1 Managing electricity
  • 2.2.2 Managing fuels
  • 2.2.3 Managing compressed air
  • 2.2.4 Managing water
• 2.3 Foundry processes and equipment
  • 2.3.1 Raw materials
  • 2.3.2 Process and material flow
  • 2.3.3 Melting
  • 2.3.4 Core making
  • 2.3.5 Mould making
  • 2.3.6 Pouring
  • 2.3.7 Sand systems
  • 2.3.8 Cleaning and finishing
  • 2.3.9 Heat treating
  • 2.3.10 Special processes
  • 2.3.11 Waste heat recovery
• 2.4 Foundry buildings
  • 2.4.1 Heating
  • 2.4.2 Air management
  • 2.4.3 Insulation
  • 2.4.4 Lighting

3.0 Putting it all Together: Closing the Gaps

• 3.1 Identifying energy management opportunities (EMOs)
• 3.2 Evaluating and calculating energy savings and other impacts of EMOs
• 3.3 Selecting and prioritizing EMO projects
• 3.4 Developing energy management programs further
• 3.5 Implementing, monitoring performance and continually improving

4.0 Sources of Assistance

• 4.1 Government
• 4.2 Canadian federal ON-SITE / À LA SOURCE professional employment assistance program
• 4.3 Universities and colleges
• 4.4 Utilities
• 4.5 Associations
• 4.6 Consultants
• 4.7 Internet
• 4.8 Other foundries

5.0 Appendices

• 5.1 Energy units and conversion factors
• 5.2 Energy benchmarks in foundries
• 5.3 Technical energy usage characteristics of electric melting furnaces
• 5.4 Calculating reductions in greenhouse gas emissions
• 5.5 Member foundries of the Canadian Foundry Association by metal type cast
• 5.6 Risk evaluation tables
• 5.7 Energy management series of NRCan publications
• 5.8 Information review

 

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