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The melting of metal and the holding of molten metal make up a substantial part of the energy consumption of a foundry.
In many foundries, more energy is consumed to keep the metal in a molten state, as in the actual melting process.
In addition, significant amounts of energy are consumed in other areas than the metal provisioning. Foundries are as large consumers of compressed air.
Other large energy consumers are likely high pressure die casting machines, which mainly hydraulic parts are also electrically operated. Sand and mould foundries can
use hot core manufacturing processes, such as mask core and hot-box cores, that use gas or electricity for heating the boxes. The heating of die cast moulds,
pans and oven linings may account for a significant part of total energy consumption.
The data from two foundry examples show, that the remaining foundry processes - except the melting and holding - are responsible for almost half of the energy
consumption of a foundry. This includes activities with motors and drive equipment, compressed air, lighting, space heating and boiler systems.
Energy efficiency measures should capture both areas - smelter and remainig processes. [UBA GI (2004). S. 263]
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