Appendices

Appendix 5.8: Information review

The following sources complemented the development of this guidebook, and the use of selected information from them in the text is gratefully acknowledged.

Heads Up CIPEC – Focus on Foundries, Office of Energy Efficiency, Natural Resources Canada, August 1999.

Proceedings of annual general meeting, Canadian Foundry Association, 2000.

Report on Preliminary Consultations – Canadian Metalcasting Technology Roadmap – Industry Canada, Canadian Foundry Association, Canadian Die-Casters Association, Canada Centre for Mineral and Energy Technology, et al. Draft, May 1999.

Private communications, Laurence V. Whiting, Canadian Centre for Mineral and Energy Technology, October through December 2000.

Use of electricity in Canadian iron foundries, Laurence V. Whiting, Canadian Centre for Mineral and Energy Technology, June 2000.

Use of electricity in Canadian steel foundries, Laurence V. Whiting, Canadian Centre for Mineral and Energy Technology, June 2000.

Use of electricity in Canadian bronze foundries, Laurence V. Whiting, Canadian Centre for Mineral and Energy Technology, May 2000.

The cost of melting grey cast iron in induction furnaces, L.V. Whiting, R.D. Warda, P.J. Buttle and R.G. Anstie, Electric Furnace Conference proceedings, 1988.

Process, Equipment and Techniques for the Energy-Efficient Recycling of Aluminum, F.T. Gerson Limited, Canadian Centre for Mineral and Energy Technology, February 1993.

Natural gas applications for industry – hydrogen, T.J. McCann and Associates Ltd., Canadian Centre for Mineral and Energy Technology, April 1996.

Natural gas applications for industry – iron and steel foundries, T.J. McCann and Associates Ltd., Canadian Centre for Mineral and Energy Technology, April 1996.

Natural gas applications for industry – steel industry, T.J. McCann and Associates Ltd., Canadian Centre for Mineral and Energy Technology, April 1996.

Natural gas applications for industry – overview, T.J. McCann and Associates Ltd., Canadian Centre for Mineral and Energy Technology, April 1996.

Intelligent energy management for small boiler plants, Gas Technology Canada, Canadian Centre for Mineral and Energy Technology, March 1998.

Implementation of an effective mill wide energy-monitoring system, Peter Brenndorfer, Avenor Inc., Canadian Centre for Mineral and Energy Technology, December 1996.

Analyses series, Centre for the Analysis and Dissemination of Demonstrated Energy Technologies (CADDET) – Learning from experiences with …

  • …small scale cogeneration, 1995;
  • …process heating in the metals industry, 1993;
  • …process heating in the low and medium temperature ranges, 1997;
  • …industrial heat pumps, 1997;
  • …compact heat exchangers, 1999; and
  • …industrial electric motor drive systems, 1998.

Low-NOx technology assessment and cost/benefit analysis, Federal Industrial Boiler Program, Canadian Centre for Mineral and Energy Technology, October 1994.

Boilers and heaters – improving energy efficiency, Office of Energy Efficiency, Natural Resources Canada, 2001.

Success Stories, Canadian Industry Program for Energy Conservation, 2000–2001.

Annual report, Canadian Industry Program for Energy Conservation, 1999–2000.

Improving energy performance in Canada, Natural Resources Canada, 1999–2000.

The state of energy efficiency in Canada in 2001, Office of Energy Efficiency, Natural Resources Canada.

Foundry energy management, American Foundrymen’s Society, 1982.

Tips for energy managers, Office of Energy Efficiency, Natural Resources Canada, 1998.

Energy efficiency planning and management guide, Canadian Industry Program for Energy Conservation (CIPEC), Office of Energy Efficiency, Natural Resources Canada, 2002.

Monitoring and target setting – implementation manual, Energy Efficiency Office of Department of Energy, U.K., 1991.

Development of Energy Intensity Indicators for Canadian Industry, 1990–1996, The Canadian Industrial Energy End-Use Data and Analysis Centre, Simon Fraser University, B.C., 1997.

Statistics Canada, selected information, 2000.

Best Practice Program, Guide 126, Compressing air costs, Energy Efficiency Office of Department of Energy, U.K., 1991.

International standards for environmental management systems ISO 14001:1996 and ISO 14004:1996, International Organization for Standardization, Geneva.

International standards for quality management systems ISO 9000:1994 and ISO 9001: 2000, International Organization for Standardization, Geneva.

Energy efficiency opportunities in … – a series of guidebooks, published by industry associations and funded by the Office of Energy Efficiency, Natural Resources Canada:

  • …the solid wood industries, The Council of Wood Industries, 1997;
  • …the Canadian rubber industry, Tire Technologies Inc., The Rubber Association of Canada, 1997;
  • …the Canadian brewing industry, Lom & Associates Inc, The Brewers Association of Canada, 1998;
  • …the dairy processing industry, Wardrop Engineering Inc, The Dairy Council of Canada, 1997;
  • …in the kraft pulp industry, Agra Simons Ltd., The Pulp and Paper Technical Association of Canada, 1998; and
  • …in aluminum smelters, Soprin-ADS, Aluminum Association of Canada, April 1998.

Analysis reports by CADDET, made available through the Office of Energy Efficiency, Natural Resources Canada:

  • Small-scale cogeneration, AR 01;
  • Process heating in the metals industry, AR 11;
  • Process heating in low and medium temperature ranges, AR 22;
  • Industrial heat pumps, AR 23;
  • Industrial electric motor drive systems, AR 24; and
  • Compact heat exchangers, AR 25.

Excerpts from 122 reports on various energy-using systems and novel foundry practices, extracted from CADDET’s on-line register (http://www.caddet-ee.org):

  • Energy efficient design of a new production facility at Scan Coat A/S, Denmark, 2000;
  • Computer-aided advance runner design, U.K., 2000;
  • Mechanical grit blasting of steel constructions without compressed air, The Netherlands, 1997;
  • Heat treatment furnace using pulse firing, Canada, 1997;
  • Heat recovery in an iron foundry at Sperre St. Yperi, Norway, 1995;
  • Regenerating fluxing fluids in thermal galvanization, The Netherlands, 2000;
  • Heat recovery in galvanizing foundries, The Netherlands, 2000;
  • Heat recovery by means of a rotary heat exchanger in an iron foundry, Norway, 1995;
  • The use of computerized modeling and solidification simulation at Hanson Foundry (Stockport) Ltd., U.K., 1994;
  • Reclamation of foundry sand using natural gas, Canada, 1999;
  • Use of molten metal filters in non-ferrous foundries, U.K., 1996;
  • Variable speed drive on a large continuous furnace combustion air fan, U.K., 1994;
  • Gas-fired scrap preheater in an iron foundry, Canada, 1999;
  • Foundries benefit from new infrared mold coating dryer, U.S.A., 1996;
  • Efficient continuous heat treatment furnace for metal products, Japan, 1997;
  • Continuous ring foundry process for brass, The Netherlands, 1997;
  • Ceramic insulation replaces firebrick in metal heat treating electric furnaces, U.S.A., 1997;
  • Lost foam casting, U.S.A., 2000;
  • Ladle lining with a lightweight insulating refractory material, U.K., 2000;
  • Compressed air costs reduced by automatic control system, U.K., 1995;
  • Compressed air leakage reduction using electronic condensate drain taps, U.K., 2000;
  • Compressed air savings through leakage reduction and the use of high efficiency nozzles, U.K., 2000;
  • Ultrasonic detection of compressed air leaks, Australia, 1999;
  • Heat recovery from an air compressor, New Zealand, 1995;
  • The performance of a variable speed air compressor, U.K., 2000;
  • Variable speed drive for an air compressor reduces electricity consumption, Denmark, 1998;
  • Expanding an existing compressed air grid with a low pressure section, The Netherlands, 1997;
  • Fuel-based nitrogen generator demonstrated in a metal industry, U.S.A., 1995;
  • A monorail transport system at a galvanizing foundry, The Netherlands, 2000;
  • Installation of a chiller and four rotary-drum air dryers, Canada, 2000;
  • Control optimization, U.K., 1994;
  • Cascaded use of waste heat from gas turbine cogeneration by steam expander, Japan, 1999;
  • Energy recovery unit for wide range of industries, New Zealand, 1997;
  • Energy management system at Volvo-Car, The Netherlands, 1996;
  • Supersavers: a workforce-led initiative to save energy and reduce waste, U.K., 2000;
  • Energy monitoring system, Canada, 1999;
  • Energy efficiency from induction melting technology, Australia, 1999;
  • Gas-fired furnaces for light alloy melting and holding processes, U.K., 1994;
  • Use of dual function burner and oxygen lance in an electric arc furnace, U.K., 1995;
  • Regenerative type heat recuperation in a retort furnace, Canada, 1997;
  • The use of oxygen/natural gas-fired burners on an electric arc furnace, U.K., 1996;
  • Long campaign hot-blast cupolas in iron foundries, U.K., 1999;
  • Cupola melting of cast iron, U.K., 1994;
  • Electric induction furnaces replace coke-fired cupolas for iron melting and lower foundry energy, U.S.A., 1991;
  • Electromagnetic induction furnace at Fonderie Grand-Mère Ltée, Canada, 1999;
  • Gas-fired furnaces for light alloy melting and holding processes, U.K., 1994;
  • Arkansas aluminum mould and die casting producer installs electric resistance melting furnaces, U.S.A., 1996;
  • Coreless induction furnaces provide flexibility and energy savings in batch melting of iron, U.S.A., 1996;
  • The conversion of two coke-fired cupolas to cokeless (gas-fired) melting at Hunt Bros. (Oldbury) Ltd., U.K., 1996;
  • Replacing a coke-fired crucible furnace with a natural gas/oxygen drum furnace, The Netherlands, 1997;
  • Speed controlled flue gas blower in an aluminum factory, The Netherlands, 1992;
  • Saving energy by partial ventilation of spraying booths, The Netherlands, 1994;
  • Improving dust collection systems at an aluminum plant, U.S.A., 1999;
  • Raising employees’ awareness at Rover Group Ltd., U.K., 1995;
  • Energy and utility management at the Royal Mint, U.K., 1994;
  • A Biotox installation at an anode preparation plant, Canada, 1999;
  • Dual-fuel rotary furnace using natural gas and carbon monoxide, Canada, 1999;
  • Conflict control of a combustion air fan on a large continuous furnace, U.K., 1999;
  • Full-time regenerative burner system (FFR), Japan, 1997;
  • Gas motor generates electricity from outlet gas in ferrous alloy production, Norway, 1996;
  • Expert system improves performance of plant controlled by programmable logic controllers, U.K., 1994;
  • Efficient continuous heat treatment furnace for metal products, Japan, 1993;
  • Waste wood as an iron-ore palletizing kiln fuel, U.S.A., 1990;
  • A rotating, gas-fired oxy-fuel furnace for the production of Ni-resist and nodular cast iron, The Netherlands, 1992;
  • Efficient ignition of a sintering furnace for crude steel production, Japan, 1990;
  • Improving efficiency of tube drawing bench, U.S.A., 1999;
  • Adjustable speed drives improve ventilation at a metal plating facility, U.S.A., 1996;
  • Training of staff reduces waste at British Aerospace (Airbus) Ltd., U.K., 1995;
  • Demand side management (DSM) technology benefits steel producer, Canada, 1992;
  • Heat pump used to drain contaminated sludge in a steel factory, Canada, 1999;
  • Expert furnace optimization process, Canada, 1999;
  • Improved casting and enhanced energy efficiency with power ultrasound, U.K., 1999;
  • Improving steam turbine performance at a steel mill, U.S.A., 1999;
  • Suction cooling roll for continuous annealing line, Japan, 1999;
  • Demonstration of innovative equipment to decoat scrap aluminum, U.S.A., 1996;
  • Preheating of the combustion air in rotary furnaces, Canada, 1999;
  • Distributed small-scale CHP (combined heat and power) in a large manufacturing plant, U.K., 1999;
  • Heat transformer in the steel industry, The Netherlands, 1995;
  • Combined heat recovery and flue gas scrubbing unit, Norway, 1995;
  • Regenerative gas-fired burner for industrial furnaces reclaims waste heat from exhaust gases, U.S.A., 1990;
  • Electricity production by heat recovery at a ferrosilicon plant, Norway, 1989;
  • Using waste heat in a stud bolt factory, The Netherlands, 1991;
  • Radiation heater with heat recovery, The Netherlands, 1991;
  • Speed-controlled flue gas blower in an aluminum factory, The Netherlands, 1994; and
  • Compressed air system combined with cogeneration in factory, Japan, 1994.

How to succeed – your process integration, water, effluent and energy study, S. Gennaoui, Proceedings of Canada’s Energy Efficiency Conference 2000.

Thermal energy savings through process integration, C. Leroy, CANMET Energy Diversification Research Laboratory, 2000.

Reports and fact sheets published by the Canadian Centre for Mineral and Energy Technology (CANMET):

  • High energy-efficient AC motors (FS10);
  • Adaptive VAR compensator (FS12);
  • Energy-efficient recycling of aluminum (FS17);
  • Heat management technologies – heat-smart solutions (FS19); and
  • Gas technologies for industry (FS20).

Newsletters by the international Centre for the Analysis and Dissemination of Demonstrated Energy Technologies (CADDET):

  • Compressed air: savings of 30% are quite normal, The Netherlands, 1999;
  • Compressed Air Challenge™ communicates better management, U.S.A., 1999;
  • Upgrading industrial waste heat using a hybrid heat pump, Norway, 2000;
  • Energy audit programs – one answer to Kyoto Protocol commitments, Finland, 2000;
  • Free CHP (combined heat and power) saves energy for vehicle manufacturer, U.K., 1998;
  • Energy recovery from dust-laden gas with self-cleaning boiler, Norway, 1999;
  • Power savings in a steelworks by using less compressed air, Japan, 1999;
  • Saving by outsourcing, Norway, 1999;
  • Electricity consumption of compressed air reduced by 60%, Denmark, 1999; and
  • Compressed air system from “Demand Back Through Supply”, Belgium, 1998.

Presentation to the Canadian Soft Drinks Association, V.G. Munroe, Office of Energy Efficiency, Natural Resources Canada, 1997.

CAN/CSA-Q850-97 Standard, Risk Management Guideline for Decision-Makers, 1997.

Do your product development math, Reinertsen & Associates, Machine Design, May 1998.

The use of the above listed sources is also recommended to any reader wishing
to obtain further information.

 

Previous | Table of Contents | Next