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Module 3:
A closer look at the
Cleaner Production process
CASE
STUDY
Midland Metals
Enterprise Profile:
country
sector
Zimbabwe
Foundry
ownership Family-owned
established 1998
employees 16
revenue
US $65,000
Midland Metals
CASE STUDY
A foundry is:
a factory that pours molten metal into
molds, producing cast metal objects.
Casting is one of the oldest industrial processes
There are different casting processes.
The focus here is: GREEN SAND CASTING
Some
typical
cast metal
objects:
Aluminum
pots
Engine blocks,
axles
low tech
Turbine blades
in jet engines
high tech
5
Background: SAND-CASTING
Midland Metals
CASE STUDY
Sand,
mixed with clay binder &
water (so it will hold its
shape) plus coal dust to
improve surface finish
Container of molten
(filled from furnace)
metal
Background: SAND-CASTING
Midland Metals
CASE STUDY
THEN
MOLDING:
Sand placed
into bottom
mold form &
compacted
2 MOLDING:
Background: SAND-CASTING
3
MOLDING:
Add the top
mold form
Midland Metals
CASE STUDY
A tube or pipe
provides a path to
pour the metal in
4
Improving MSME Performance through Cleaner Production. Module
3: A Closer Look at CP. Visit www.encapafrica.org.
Background: SAND-CASTING
5
MOLDING:
Take the top
mold off and
remove pattern
& pipe or post
Pouring
hole
6
Improving MSME Performance through Cleaner Production. Module
3: A Closer Look at CP. Visit www.encapafrica.org.
Midland Metals
CASE STUDY
Background: SAND-CASTING
8
7
CASTING:
Pour the metal (container is
filled from furnace immediately
before you are ready to pour)
Midland Metals
CASE STUDY
Midland Metals
CASE 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.
11
Background: SAND-CASTING
Midland Metals
CASE STUDY
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!
12
Midland Metals
Enterprise Profile, contd:
products
Production
volume
Markets
Midland Metals
CASE STUDY
3-15cm
(mill balls)
Improving MSME Performance through Cleaner Production. Module
3: A Closer Look at CP. Visit www.encapafrica.org.
13
Midland Metals
CASE STUDY
Sand mixing
area
Molding
Molding Section
section
Casting area
Gases, organic
fumes
liquid metal
Energy
INPUTS
Shake-out &
Cleaning area
Finished
products
Non-Product
OUTPUTS
*Bentonite is a mineral clay.
It forms a binding agent
when mixed with water.
14
Midland Metals
CASE STUDY
15
OUTPUTS
Energy
- Electricity = 6 MWh
Raw materials
- New sand = 135 t
- Old sand = 540 t
- Coal dust = 55 t
- Bentonite = 55 t
- Water = 40,320
litres
Midland Metals
CASE STUDY
Emissions to the
atmosphere
- Dust = 30 t
SAND
MIXING
PROCESS
(mostly
manual)
Waste
- Used sand = 105
t
Products
- Moulds and
cores = 672
tonnes
Annual
figures
16
Midland Metals
CASE STUDY
Quantity
per 50 kg
batch (kg)
Annual quantity*
(kg)
New Sand
10
134,400
0.02
2,677
Old Sand
40
537,600
Bentonite
53,760
0.17
9,027
Coal Dust
53,760
0.07
3,673
3 litres
40,320 litres
0.02
840
Total
16,217
Water
Unit cost
(US$/kg)
Annual
Total cost
(US$)
17
Biggest CP opportunities
Waste of raw material (sand)
During mixing stage
Spillage
Dust
Midland Metals
CASE STUDY
loss = 2000 kg
! 25%
sand per ton product
18
Midland Metals
CASE STUDY
Annual savings (US$)
Good housekeeping
Input
substitution
278
116
Equipment modification
139
185
28
28
232
$1005
19
Midland Metals
CASE STUDY
Old system:
Manual sand
reclamation & mixing
Roller sand mixer +
accessories + shipment
$8,106
Sand shaker
$3,706
$347
2 x 5 kW motor
$926
10 m conveyor belt
$694
$463
$1,158
Installation costs
$810
Contingencies
$1,621
$17,833
Molds
shaken out
Shaker table
with Screen
Conveyo
r
Belt
(Removes
lumps)
(Transports
sand)
New system:
Mechanical
sand reclamation plant
Hopper
(Feeds sand
to mixer)
Mechanical
Sand Mixer
20
Midland Metals
CASE STUDY
INPUTS
Energy
Electricity=24MW
Increase
h
from 6 MWh
Raw materials
- New sand = 65 t
was - Old sand = 610 t
135 - Coal dust = 55 t
t - Bentonite = 55 t
- Water = 40,320
litres
OUTPUTS
Emissions to
the atmosphere
was 30 t
- Dust = 15 t
SAND
MIXING
process
Waste
- Used sand = 50
t
was
105
t
(mechanized)
Products
- Moulds and
cores = 672
tonnes
21
Profitability analysis:
Mechanical sand reclamation/mixing
INVESTMENT COST
Vs.
$17,833
Midland Metals
CASE STUDY
SAVINGS (annual)
31.25% saving on labor
$3,543
$8,351
Lower overall
operating costs*
$2,630
ANALYSIS
Payback Period
Net Present Value (@20%, 5 years)
Internal Rate of Return
$14,525
<2 years
$25,606
77%
22
Midland Metals
CASE STUDY
1. Improved Profitability
23