Energy Resilient Foundries: The 'Small is Beautiful' Projects

Applying the concept of “small is beautiful” into a conservative relatively low technology manufacturing sector where the “economies of scale” argument has been used to build ever more so-called efficient process lines is a major challenge. The energy efficiency of the casting process has only been investigated in a limited fashion. The two “Small is Beautiful” projects aimed to introduce a new concept into foundries with regards to the use of their resources. The new philosophy, “small is beautiful”, starts by encouraging the use of high-quality feedstock, only melting what is required and only when it is required. Recycling of internal scrap is not necessarily acceptable but an aim for higher yields is. Applying counter gravity casting methods to improve yield and give enhanced quality is encouraged as is the recovery of low-grade heat from solidification. The present paper discusses the research undertaken and the key findings from the two projects.