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Metal Casting Melting Furnaces Table A2.16 - Assumptions for Calculating Energy Consumption and Off-gas Waste Heat Losses in Selected Metal Casting Furnaces Aluminum Reverberatory Furnace Stack Melter 2,633,613 Iron Cupolaa Low efficiency cupola High efficiency cupola 6,076,119 Production Production (tons/year)b (%)c Production (tons/year) (TBtu/Year) Temperaturee FC Estimated Percentage of Energy Consumption (10^6 Btu/ton)b Energy Consumption adjusted for yield (10^6 Btu/ton)d Energy Assumed Average Consumption Exhaust 90% 10% 2,370,252 263,361 3.61 1.95 8.03 4.33 19.0 2100 1150 80% 4,860,895 5.76 9.6 46.7 1650 7.8 400 900 204 6.4 a. Schifo, J., 2004. Theoretical/Best Practice Energy Use in Metalcasting Operations, p. 28. Paper describes two types of cupolas: high efficiency and low- 20% 1,215,224 3.84 efficiency cupolas. Approximately 20% of cupolas can be approximated as "high efficiency". It is assumed that all high efficiency cupolas include a recuperative air preheat system. b. Secondary aluminum production based on ratio of shape casting to total production reported by BCS, 2003. US Requirements for Aluminum Production: Historical Perspective, Theoretical Limits and New Opportunities. Tables A2. 2003. Current aluminum production data from Plunkert, P., 2007.USGS Mineral Commodity Summaries: Aluminum. Year 2006 estimate. Iron cupola production data from Schifo, p. 30. c. Schifo, pp. 30-39. d. Assumes 45% yield for aluminum casting, based on BCS 2003, Table F2, and 60% in iron casting, based on Schifo, p. 30. 3. Secondary aluminum temperature without heat recovery from Wechsler, T. and Gitman, G. 1990, "Use of the Pyretron Variable Ratio Air/Oxygen Fuel/Burner System for Aluminum Melting." Paper presented at the Aluminum Industry Energy Conservation Workshop XI. Jacksonville Florida November 1990. Stack melter exhaust temperature from Schifo, p. 40. Iron cupola exhaust temperatures from personal communication with Eppich, B. Eppich Technologies. A-19 1.1 325 160PDF Image | Waste Heat to Energy Tech Opportunities in US Industry
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