Simulation of non-ferrous melting and die-casting plants for energy efficiency

摘要

Evaluation of intralogistic energy saving measures with a material flow simulator and an included thermodynamic model of the melting furnaces. In order to stay competitive on the world market a high level of automation and energy efficiency is essential for energy-intensive industries. The impact of energy efficiency has increased in Germany in particular as a result of the energy transition and the strengthening competition based on globalization. In the non-ferrous melting and die-casting industry for example the energy consumption per ton of good casting usually ranges between 2000 and 6000 kWh. Consequently, the amount of energy costs generally exceeds 25% of gross value added. Up to 60% of this energy is needed for the factory-internal melting process of the aluminum, which usually takes place in gas-fired secondary aluminum melting furnaces. Thereby problems are generally determined by the lack of information on the production fluctuations in the foundry which are caused by the complex requirements for liquid aluminum. Consequently the furnaces are frequently driven outside the ideal operating range and energy is wasted. Obviously the production process needs to be optimized by appropriate intralogistic control measures which lower the energy consumption without impairing productivity. Control strategies can be evaluated with the help of a material flow simulator which includes an additional function for the energy consumption of the melting process.