The current energy crisis and high fossil fuel costs are challenging energy intensive industries such as non- ferrous foundries. It is therefore important to promote the transition to renewable energy sources with the electrification of melting units. This pilot study is the first to simulate the transition of conventional foundries to sustainable technologies. For this purpose, a simulation model based on a selected example company is developed. It takes into account 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. The effects of efficiency as well as energy costs and emissions are also taken into account.

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.