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Improving BSO Services and SME Performance Through Cleaner Production

Explore how the foundry Midland Metals in Zimbabwe applies green sand casting, its processes, equipment, and challenges. Learn about the production volume, inputs, and outputs in the foundry process. Discover the steps involved in sand casting and the importance of cleaner production in the industry.

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Improving BSO Services and SME Performance Through Cleaner Production

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  1. Improving BSO Services and SME Performance Through Cleaner Production [SPEAKERS NAMES] [DATE]

  2. Module 3: A closer look at the Cleaner Production process

  3. CASE STUDY “Midland Metals” Enterprise Profile: country Zimbabwe sector Foundry ownership Family-owned established 1998 employees 16 revenue US $65,000 Based on case study created by the United National Environment Program, Division of Technology, Industry and Economics Improving MSME Performance through Cleaner Production. Module 3: A Closer Look at CP. Visit www.encapafrica.org.

  4. Midland MetalsCASE STUDY Background: What is a Foundry? A foundry is: • Casting is one of the oldest industrial processes • There are different casting processes. The focus here is: “GREEN SAND” CASTING a factory that pours molten metal into molds, producing cast metal objects. Aluminum pots Engine blocks, axles Some typical cast metal objects: Turbine blades in jet engines “low tech” “high tech” Improving MSME Performance through Cleaner Production. Module 3: A Closer Look at CP. Visit www.encapafrica.org.

  5. Midland MetalsCASE STUDY Background: SAND-CASTING Basic materials & equipment for green sand-casting Pattern (a copy of the shape you want to produce, made of wood, plastic or metal) Sand, mixed with clay binder & water (so it will hold its shape) plus coal dust to improve surface finish Container of molten metal(filled from furnace) Top and bottom mold forms(made of metal, open at top and bottom) Rammer (tool to compact the sand; often a pressing machine is used) Improving MSME Performance through Cleaner Production. Module 3: A Closer Look at CP. Visit www.encapafrica.org.

  6. Midland MetalsCASE STUDY Background: SAND-CASTING A very basic summary of the sand casting process. . . First of all, mix the sand. THEN 1 MOLDING:Pattern placed into mold MOLDING:Sand placed into bottom mold form & compacted 2 Improving MSME Performance through Cleaner Production. Module 3: A Closer Look at CP. Visit www.encapafrica.org.

  7. Midland MetalsCASE STUDY Background: SAND-CASTING MOLDING: Add the top mold form 3 A tube or pipe provides a path to pour the metal in Pattern is still inside! 4 MOLDING: Fill top form with compacted sand. Improving MSME Performance through Cleaner Production. Module 3: A Closer Look at CP. Visit www.encapafrica.org.

  8. Midland MetalsCASE STUDY Background: SAND-CASTING In the middle of the sand is a cavity shaped like the pattern! MOLDING: Take the top mold off and remove pattern & pipe or post 5 Pouring hole 6 MOLDING: Replace the top mold and fasten securely! Improving MSME Performance through Cleaner Production. Module 3: A Closer Look at CP. Visit www.encapafrica.org.

  9. Midland MetalsCASE STUDY Background: SAND-CASTING 8 Wait for the metal to cool(minutes to days, depending on the size of the casting) 7 CASTING:Pour the metal (container is filled from furnace immediately before you are ready to pour) Improving MSME Performance through Cleaner Production. Module 3: A Closer Look at CP. Visit www.encapafrica.org.

  10. Midland MetalsCASE STUDY Background: SAND-CASTING A copy of the pattern has now been made in metal 9 CLEANING. Sand is cleaned off the part, the “tab” where metal flowed in must be removed. 10 8 SHAKE OUT: Break apart the two halves of the mold & take out the part—usually requires vibrating or striking the mold to break apart the sand Mold forms are reused Sand is broken up, screened to remove debris and clumps, and sent for remixing 11 Improving MSME Performance through Cleaner Production. Module 3: A Closer Look at CP. Visit www.encapafrica.org.

  11. Midland MetalsCASE STUDY Background: SAND-CASTING Sand-casting is simple in concept, but demanding in execution. It is a process essential to making basic and advanced products. . . it is also hazardous and energy-intensive! Improving MSME Performance through Cleaner Production. Module 3: A Closer Look at CP. Visit www.encapafrica.org.

  12. Midland MetalsCASE STUDY Midland MetalsEnterprise Profile, cont’d: Iron mill balls & crushing hammers(used for crushing ore) products Production volume 25 tons/month(planning 10-fold expansion) Markets Mining sector 3-15cm (mill balls) Improving MSME Performance through Cleaner Production. Module 3: A Closer Look at CP. Visit www.encapafrica.org.

  13. Midland MetalsCASE STUDY Foundry process map Sand (new/old), bentonite*, coal dust, water, energy Dust, gases, noise, reject mixed sand, surplus sand Sand mixing area Patterns, mold forms, sand filling, coatings, energy Dust, gases, surplus sand, noise, rejected molds Molding section Molding Section liquid metal Gases, organic fumes Casting area Shake-out &Cleaning area Dust, gases, mold forms, used sand Energy Non-ProductOUTPUTS INPUTS Finished products *Bentonite is a mineral clay. It forms a binding agent when mixed with water. Improving MSME Performance through Cleaner Production. Module 3: A Closer Look at CP. Visit www.encapafrica.org.

  14. Midland MetalsCASE STUDY Initial CP assessment findings • Sand contains significant amount of dust • Wind blows sand and dust from stock piles • Workers estimate quantities for sand binder and hardener • Energy consumption of furnaces higher than normal for similar operations • Furnace tap-hole not well sealed after use • Liquid metal spills during filling of molds • Large number of rejects • Sand is lost in each cycle • Sand mixing and reclamation very labor intensive Improving MSME Performance through Cleaner Production. Module 3: A Closer Look at CP. Visit www.encapafrica.org.

  15. Midland MetalsCASE STUDY Material balance for sand mixing INPUTS OUTPUTS Energy - Electricity = 6 MWh SAND MIXING PROCESS (mostly manual) Emissions to the atmosphere - Dust = 30 t Raw materials - New sand = 135 t - Old sand = 540 t - Coal dust = 55 t - Bentonite = 55 t - Water = 40,320 litres Waste - Used sand = 105 t Products - Moulds and cores = 672 tonnes ! only 75% reclamation efficiency (25% of sand in each batch is lost.) Annual figures Improving MSME Performance through Cleaner Production. Module 3: A Closer Look at CP. Visit www.encapafrica.org.

  16. Midland MetalsCASE STUDY Sand Mixing: Raw materials costs (*56 batches/day x 240 days/yr) ! New sand = 17% of raw material costs Improving MSME Performance through Cleaner Production. Module 3: A Closer Look at CP. Visit www.encapafrica.org.

  17. Midland MetalsCASE STUDY Biggest CP opportunities • Waste of raw material (sand) • During mixing stage • Spillage • Dust • Inefficient use of labor • Manual sand mixing • Manual screening for sand reclamation • RESULT: 4 man-hours required to mix 1 batch ! 25% loss = 2000 kg sand per ton product Improving MSME Performance through Cleaner Production. Module 3: A Closer Look at CP. Visit www.encapafrica.org.

  18. Midland MetalsCASE STUDY Rapid payback CP opportunities Annual savings (US$) Good housekeeping Cover the new sand 278 Implement more thorough inspection, segregation of incoming scrap 116  Input substitution  Use sand with low dust content 232 Optimize furnace-melting conditions 139 Train workers to properly handle and measure sand binder & hardner 185 Better process control  Equipment modification  Improvise proper closing mechanism for furnace taphole 28 Install goods spouts on melting pots 28 Total annual savings: $1005 Improving MSME Performance through Cleaner Production. Module 3: A Closer Look at CP. Visit www.encapafrica.org.

  19. Midland MetalsCASE STUDY Capital investment CP opportunity:Mechanical sand reclamation/mixing Old system: Manual sand reclamation & mixing Molds shaken out Shaker table with Screen (Removes lumps) Conveyor Belt (Transports sand) New system:Mechanicalsand reclamation plant Hopper (Feeds sand to mixer) Mechanical Sand Mixer Improving MSME Performance through Cleaner Production. Module 3: A Closer Look at CP. Visit www.encapafrica.org.

  20. Midland MetalsCASE STUDY NEW sand mixing material balance INPUTS OUTPUTS SAND MIXINGprocess (mechanized) Energy - Electricity=24MWh Emissions to the atmosphere - Dust = 15 t was 30 t Increase from 6 MWh Waste - Used sand = 50 t was 105 t Raw materials - New sand = 65 t - Old sand = 610 t - Coal dust = 55 t - Bentonite = 55 t - Water = 40,320 litres was 135 t Products - Moulds and cores = 672 tonnes Improving MSME Performance through Cleaner Production. Module 3: A Closer Look at CP. Visit www.encapafrica.org.

  21. Midland MetalsCASE STUDY Profitability analysis:Mechanical sand reclamation/mixing INVESTMENT COST Vs. SAVINGS (annual) $17,833 *even with increase in electricity costs ANALYSIS Improving MSME Performance through Cleaner Production. Module 3: A Closer Look at CP. Visit www.encapafrica.org.

  22. Midland MetalsCASE STUDY Benefits of Cleaner Production • Improved Profitability • Raw material saving of 25% • Labour costs cut by 30% • Reduced plant and equipment maintenance costs • Improved product quality • 5 to 7 fold increase in production levels (pieces/per day), so total profits increase 5 to 7 fold as well • Reduced environmental impact Improving MSME Performance through Cleaner Production. Module 3: A Closer Look at CP. Visit www.encapafrica.org.

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