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1 SURVEY OF CHEMICAL EMISSIONS The metalcasting industry is, by nature, very energy intensive. Metalcasting processes include melting, remelting, and heat-treating castings, which are very energy-intensive processes. The energy used by metalcasting facilities in the United States was determined to be 236 trillion Btu in the Manufacturing Energy Consumption Survey of 1998 at production volumes similar to 2003. Many studies have been undertaken during the last 15 years to determine the energy profile of the metalcasting industry, with varying results. Many casting facilities have other value-added processes in addition to the foundry operations. It is difficult to compare all of the energy usage associated with casting specific processes. Table 60 provides an estimate of the 2003 metalcasting energy uses and CO2 emissions. Table 60. Estimated 2003 Metalcasting Energy Usage and CO2 Emissions Gray Iron Ductile (other than pipe) Ductile Iron Pipe Al High Pressure Die Al Permanent Mold/Sand Mg Die Casting Zinc Die Casting Copper-Base; Sand 29.7 5,477,808 162.6 26.0 2,016,128 52.4 7.8 2,000,000 15.7 60.6 1,585,720 96.0 99.4 373,266 37.1 67.8 106,600 7.2 23.4 344,000 8.0 37.3 311,600 11.6 106 Btu/Ship (Ton) Ship (Tons) 2003 Benchmark Tacit Energy 1012 (Btu) Tons 103 Tacit Energy 2003 Estimated CO2 11,187 3,494 1,160 Steel 36.5 1,257,660 45.9 2,993 6,217 Casting 1,372 Al Lost Foam 81.9 304,014 24.9 1,613 486 515 780 Titanium 65.0 40,977 2.7 187 Other Non-Ferrous 22.5 86,227 1.9 353 Energy Use in Select Metalcasting Facilities. 2003. The emission of CO2 in million metric tons per quadrillion Btu of energy consumed in 2003 was 68.53, an increase of 0.5 from 1998. Table 61 shows total industry emissions. Table 61. Estimated Total Emissions from the Mining and Metal Processing Industry U.S. Environmental Protection Agency. U.S. Inventory of Greenhouse Gases, Washington: Government Printing Office. April 15, 2003. All values reported in Tg CO2 Eq = Teragrams of Carbon Dioxide equivalent. Industry Type Gas Emissions 1990 2001 Ferroalloys CO2 2.0 1.3 Coal Mining CH4 87.1 (230 PJ) 60.7 (161 PJ) Silicon Manufacturing CH4 - - Aluminum Production HFCs, PFCs, SF6 18.1 4.1 Mg Production & Processing HFCs, PFCs, SF6 5.4 2.5 Metals Manufacturing NOx, CO, VOC 2.6 1.3 58PDF Image | Analysis for Recovering Energy from Industrial Waste Heat
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