TDI Energy Solutions

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Products: AFS Energy Solutions Program

Furnace Operations - Improving Efficiency and Throughput

A key component of the AFS Energy Solutions Program is an innovative sub-metering technology designed specifically to find savings opportunities in foundries.

The electricity required to melt the metal for your casting is based on the pour weight, which can be significantly higher than the casting weight, depending on gating and risering. Energy accounts for about 5-7% of operating cost and more than 50% of that cost is melting.

What We Can Do For You:

           Sub-metering system

           Sub-metering system

We reveal how you are actually using electricity, compressed air, dust collection equipment, natural gas, etc. and correlate that to your plant operations. Improve efficiency and throughput of the entire plant, and save energy at the same time. Get real-time alerts whenever unsatisfactory conditions occur.

Unique metrics developed were specially developed for foundry management under AFS R&D project 12-13.  Many other metrics are also available from the project:

Furnace Operations Metrics

  • Amount of Time Furnace is Off
  • Amount of Time Furnace is On Hold
  • Amount of Time Furnace is at Half Power
  • Amount of Time Furnace is at Full Power
  • Average Time from Tap to Tap
  • Summarized by Day, Week, Shift, etc.

 

Do you currently have this kind of information for this critical activity?

                        Induction furnace operations

                        Induction furnace operations

Reverb furnace photo supplied by Schaefer Furnaces Division of The Schaefer Group, Inc.

Reverb furnace photo supplied by Schaefer Furnaces Division of The Schaefer Group, Inc.

Energy Cost Metrics

  • Per Ton per Heat
  • Tap to Ready
  • Tap to Tap
  • Ready to Tap
  • Per Alloy
  • Summarized by Day, Week, Shift, etc.

Real-time Alerts (text, e-mail)

  • Equipment On or Off for more than a specified time
  • Total energy use exceeding defined thresholds
  • Many other metrics are also available


TDI Consulting, Inc.     Toll Free: 877-343-1580