Green Melting - Pilotstudie zur Elektrifizierung von Leichtmetallgießereien durch lokales induktives Schmelzen

This study describes the development of an operation-independent simulation model for an electrified die-casting foundry that uses a smart grid system to meet its energy needs. The model uses real weather and stock exchange electricity price data for the simulation period. The model can be used to determine and compare the cost of electricity for production at a given time (time of day and season) as well as the economics of different PV system and electricity storage options. It is also possible to analyze the share of different energy sources for each configuration. This can be done for sites throughout Germany. In addition, exemplary simulation studies are presented in this paper which demonstrate the wide range of applications of the model. The results provide an initial overview of the potential for savings and optimization. In the future, the model will provide a basis for determining optimum plant layouts and production times by means of simulation-based optimization.

The current energy crisis and the high cost of fossil fuels pose major challenges for energy-intensive industries such as the non-ferrous foundry industry. Therefore, it is important to promote the transition to renewable energy sources with the help of the electrification of the melting units. In this pilot study, for the first time the conversion of conventional foundries to sustainable technologies is simulated. For this purpose, a simulation model is developed based on a selected example company. It considers the energy consumption and the logistical effects of a converted operation. The simulation model is implemented as a hybrid simulation combining a discrete
event simulation at the plant level and a process simulation within the furnaces. The study shows how a sustainable energy supply can be achieved in foundries. It also considers the impact of efficiency, energy costs and emissions.