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has installed a system for using waste heat to evaporate wastewater. Initially the facility had to spend about $22,000 per year to dispose of 48,000 gallons of wastewater consisting of 90% water and 10% oil. It was discovered that exhaust gases from a reverberatory furnace could be used to evaporate the water, thereby significantly reducing waste disposal costs. Figure 26 – Example of Monthly Load Profile for Natural Gas at a Casting Facility Located in the Midwest 4.5.1 Aluminum Casting Aluminum casting facilities consume about 34% of the energy consumed by the metal casting industry.121 They consume from 60 to 100 million Btu tacit energy per ton of casting shipments.122 Melting furnaces include reverberatory furnaces, stack melters, crucible furnaces, and induction furnaces. Reverberatory furnaces are the most commonly used melting furnaces among highvolume aluminum foundries and account for melting 90% of aluminum produced in the United States.123 Aluminum reverberatory furnaces have exhaust temperatures of about 2,0002,400°F [1,090°C1,316°C] and thermal efficiencies around 3035%.124 A more efficient option is the stack melter, which has a better seal and uses hot flue gases to preheat the metal charge, enabling efficiencies of 4045%.125 The temperature of exhaust gases leaving stack melters ranges from about 250 to 400oF [120204°C]. Despite the greater efficiency of stack melters, they are used in only about 5 to 15% of aluminum production.126 Some barriers to implementation include: • Increased maintenance costs: Charges loaded at the top of the stack melter drop to the bottom and cause additional wear and tear on the refractory lining. The additional labor and materials required to maintain the refractory can limit the financial savings achieved through energy efficiency.127 However, some progress has been achieved in advanced refractory materials that can better withstand impacts from falling charge material. • Charge Requirements: Due to the stacking requirements for the charge material, facilities are often unable to take advantage of lower cost charge materials.128 However, rising natural gas costs and further improvements in stack melter design may increase the cost effectiveness of stack melters and reduce the magnitude of these barriers. 35,000 30,000 25,000 20,000 15,000 10,000 5,000 0 Monthly Load Profile for Natural Gas at a Gray Iron Cupola Facility (Natural GasFired Hot Blast) Month 46 Gas Consumption (Million Btu) Aug00 Sep00 Oct00 Nov00 Dec00 Jan01 Feb01 Mar01 Apr01 May01 Jun01 Jul01PDF Image | Waste Heat to Energy Tech Opportunities in US Industry
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