China is a big foundry country in the world, but the current situation of high energy consumption, heavy pollution and poor economic benefits in China’s foundry industry is still far behind the foundry industry. Therefore, how to reduce the energy and resource consumption of  castings, improve product yield, reduce harmful substances and pollutant emissions in the production process, realize circular economy, build resource-saving and environment-friendly castings has been an important problem faced by foundry enterprises in China. Therefore, Energy Conservation& Emission Reduction is a very important issues in the development of traditional investment casting industry.

Clean production aims to reduce or eliminate the harm to human health and environment by continuous measures, such as using clean energy and raw materials, adopting advanced technology and equipment, improving management, comprehensive utilization and  resource utilization, reducing  or avoid pollution sources and discharge of pollutants in production, service and product use.

 Energy conservation and emission reduction project implementation and potential analysis

In order to effectively promote green manufacturing, our company mainly focuses on the traditional water glass investment casting process, energy-saving,environmental protection technology, equipment technology research and clean energy application. For example, our company study on Waste water treatment and reuse, non baked shell casting process transformation, coal gas instead of clean energy application to continuesly promote their technological progress. Clean production is the guarantee of sustainable development of enterprises, and also the primise of energy conservation and emission reduction. The selection of technical transformation conforms to the national industrial policy and local development plan.

The waste water of wax mold production mainly comes from cooling and cleaning waste water, dewaxing and recovery waste water, shell making process cleaning, hardening liquid brought by workpiece, surface cleaning waste water, etc. The melting process mainly comes from medium cooling water. The hydraulic system of Variable frequency electric furnace leaks from time to time. Consequently, the waste water contains petroleum pollutants; the waste water of heat treatment process mainly contains some organic salts, oil, etc.; the air compressor station mainly contains petroleum pollutants; the mechanical processing process mainly includes emulsion waste water, etc.

(1) Two 6t / h  natural gas boiler  and one 4T / h chain grate boiler coal-fired steam boiler wereused before. Since it was put into operation in the 1980s, the existing coal-fired boilers have been replaced by two gas-fired boilers.

The thermal efficiency of chain boiler is 68%. The required coal heat of the boiler is as follows:

The calorific value of natural gas is calculated as 8500 kcal / nm. The natural gas demand after the transformation is as follows:

Energy saving equivalent standard coal of gas boiler instead of coal: 3564-2753 = 811tce

(2) Before the reform of the roasting system, the company used the gas of the producer as the roasting fuel in the shell roasting system, and the direct roaster consumed 2080t of coal for the gas producer.

Gas volume of generator: 2080 * 3000 = 624000m

Energy saving equivalent standard coal: 1872-1337 = 535tce

2、 Energy saving effect after project implementation

Comprehensive energy saving 3033tce.

3、 Emission reduction effect after project implementation

The annual emission reduction after the project is put into operation is as follows:

The construction of the project can reduce the corresponding pollutant emissions and produce double effects of energy conservation and environmental protection. After the sewage treatment station is completed and put into use.

Our company has reduced the consumption of raw and auxiliary materials, water resources and energy, reduced the emissions of carbon and nitrogen oxides, and achieved the goal of energy conservation. To carry out energy conservation and emission reduction work, such as energy conservation and environmental protection technology, equipment technology research, clean energy application, etc., to provide reference for traditional precision casting enterprises to carry out energy conservation and emission reduction work. It has good economic and social benefits to realize energy conservation and emission reduction in the whole society.

Cleaner production process is the whole process control of resources, energy consumption and pollution discharge, which can reduce the resources and energy consumption of each production link, define and quantify pollution prevention and control, promote the technological progress of enterprises in the industry, help enterprises to self position, and determine their own resource conservation and environmental friendly performance improvement. Approaches and gaps, through market driven mechanism, mobilize the enthusiasm of enterprises to promote cleaner production, and transform cleaner production into conscious behavior of enterprises.

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