New Plant-Technologies for Reducing Carbon Emissions and Costs in Heat Treatment Processes of Aluminium Castings

摘要

The sustainable usage of our precious energy resources is one of the most challenging topics in current developments in the field of mechanical engineering. Apart from the use of a product, the requirements for reducing the impact of manufacturing activities are also increasing, not least because of their economic relevance. Energy-intensive processes, such as foundry industries, are particularly affected. In Aluminium foundries, in addition to the melting process and primary shaping, heat treatment is also of particular significance for an eco-oriented redesign of thermal processing operations. In consideration of the efficient use of energy-resources, this study focuses on the development of innovative plant technology for a sustainable heat treatment of aluminium components. In contrast to previously known solutions, the developed gas-heated furnaces (based on a newly designed burner system) can provide the necessary processing heat for the first time in an electrical control quality. Additionally, the control of the developed burner allows for the reliable utilization of hot air, and thus the effective reuse of waste heat. Conducted analyses and verifications of the prototype plant exhibit tremendous potential for reducing the energy consumption, for lowering costs (savings up to 70%) and CO_2 emissions (reduction of 60%), without adversely affecting the quality of the components.