Improved process control reduces the number of rejected (scrap) castings in the foundry. Less scrap means fewer castings need to be re-melted and re-cast. The energy needed to melt cast iron is approximately 10,000 MJ per tonne. For a foundry producing one million Engine Equivalents per year, with a mould yield of 65%, the annual energy demand for melting is approximately 800 million MJ, corresponding to more than 35,000 tonnes of coal per year. Every 1% of scrap reduction reduces the coal demand by over 350 tonnes per year – approximately 1,000 tonnes of CO2 for every one million Engine Equivalents. SinterCast helps the foundry to be right-first-time.
Foundry Weight Reduction
The increased strength of CGI allows the weight of cylinder blocks to be reduced by 10-20% compared to a conventional cast iron cylinder block. Less weight means less metal melted in the foundry. For a foundry producing one million Engine Equivalents per year, 15% weight reduction provides an annual savings of 7,500 tonnes of castings, corresponding to approximately 10,000 tonnes of liquid iron. This reduction in liquid metal demand corresponds to a saving of approximately 100 million MJ of electricity, 4,500 tonnes of coal, and 10,000 tonnes of CO2 per year.
The increased strength of CGI allows engineers to reduce weight while increasing the combustion pressure, resulting in more power per litre. Smaller CGI engines can replace larger engines while providing similar performance. This downsizing can provide weight reduction of approximately 25 kg in a passenger vehicle engine. For passenger vehicles, every 100 kg of weight reduction provides a fuel saving of approximately 0.2 litres for every 100 km driven. The 25 kg weight saving corresponds to 100 litres of saved fuel over the 200,000 km lifetime of a vehicle, providing a reduction of approximately 250 kg of CO2 per vehicle.
Weight reduction in commercial vehicles enables increased payloads; reduced vehicle-miles; and, improved fuel economy. Every 100 kg of weight reduction improves commercial vehicle fuel economy by 0.1%. For a typical 12L engine, with fuel consumption of 40 litres per 100 km, the use of SinterCast-CGI can reduce the weight by approximately 100 kg, yielding fuel savings of approximately 0.04 litres for every 100 km. With typical annual mileage of 250,000 km, the weight saving of 100 kg corresponds to a fuel saving of approximately 100 litres of diesel fuel per year – a reduction of more than 250 kg of CO2 per year and 2,000 kg of CO2 over the typical lifetime of a commercial vehicle.