Energy and Mass Flow Model PDC Foundry

1. Energy and Mass Flow ModelPDC Foundry NFTN Project: Addressing Energy Saving in the Foundry Industry using Dynamic Plant Simulation Software

2. Virtual Foundry

3. Summary of Progress • Task a) Project Partner • Foundry visited and assessed • MOA formulated and signed with PDC • Task b) Information Gathering • General foundry information gathering completed (PDC & Fred Cooper) • Constructed flow diagram • Foundry control logic completed • Data sheet report still in progress • Task c) Model Set-up • Set up general flow diagram in Plant Simulation Software SysCAD • Modifying SysCAD material data format (KWA Kenwalt) • Formulated holding and melting furnace unit models • Heat transfer to environment – convection, radiation, conduction • Simulate lid on/off • Energy heating model completed • Capturing foundry control logic in SysCAD • Melt furnace control states • Holding furnace control states • Peripheral equipment handling • Material handling control logic

4. Summary of Progress • Task d) Scenario Testing • Scenario testing criteria defined • Furnace lid on – off • Potential for smart control for holding furnaces • Test holding furnace combinations eg 1 holding furnace feeding two HPDC machines • Test hold temperature sensitivity • Size and power of melting furnaces • Test alternative for controlling melting furnaces • Test TOU scenario • Set up plant simulation control interface in Excel • Task e) Data Validation & calibration • In progress: Power and energy consumption • In progress: Cost of Power • Task f) Analyses & Reporting • In progress