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Description
Krakodlew is the largest foundry in Poland and one of the largest in Europe. It supplies over 100 steel plants around the world with metallurgical equipment, and a dozen or so leading manufacturers of cranes and excavators with weights and counterweights. The aim of the project is to implement an innovative technology of recovery, storage, and re-use of thermal energy from broken moulding mass. Thanks to the use of these solutions, Krakodlew will be able to provide its customers with castings that are cheaper, of better quality, and made in a much more accurate manner than they are made in today.
Under the project we are planning to carry out development works regarding the heat recovery system from broken moulding mass, and subsequently - the construction of this system, that is integration of its individual components and implementation of activities leading to a higher level of energy efficiency. The last element of the project is testing the entire installation, and the use of recovered thermal energy for heating water and facilities. We will reach an environmental effect by reducing the annual carbon emission by 311.03 tons, reducing the annual electricity consumption by 0.41 GWh, and reducing the amount of fresh sand used in the casting process by 276 tons.
Summary of project results
The goal of the completed project was to implement an innovative technology for recovering thermal energy from used molding sand, which will positively impact the entire technological process of manufacturing large-scale castings in the long term. This will contribute to increasing the competitiveness of Krakodlew S.A., its revenue and profit, as well as improving waste management, achieving higher energy efficiency, and reducing emissions of pollutants into the atmosphere.
The project focused on the development and implementation of: • An innovative technology for recovering and storing thermal energy from spent molding sands (process innovation), • Significantly improved large-scale plate castings, such as ladle plates and flat weights (product innovation), • Two innovative solutions: utilizing technological heat energy for central heating (C.O.) and hot water supply (C.W.U.), and ensuring stability and control of temperature conditions during the casting manufacturing process (molding technology, shakeout, and solidification of castings) through the parameterization and construction of a closed heat recovery system from the sand. The construction of the installation with a thermal energy storage system enabled the acquisition of a large amount of thermal energy, which the company uses for its ongoing operations. The installation was connected to a system that allows for the recovery of thermal energy from molds and their heating via a heat exchanger. Delivering excess heat from the sand to heat large molds results in technological advantages of the castings by reducing their porosity and improving their internal structure (directional solidification and crystallization). Recovering thermal energy from spent molding sand and castings allows for the heated water from the production process to be directed towards the central heating of company buildings and hot water supply (C.W.U.). This solution significantly reduces the amount of gas needed for water heating, thereby considerably decreasing the amount of pollutants emitted into the atmosphere. It is also important to note that any surplus thermal energy generated can be used for heating casting molds or for localized heating within the production hall.
As part of the project, the following were implemented: • An innovative technology for recovering and storing thermal energy from spent molding sands, and innovative solutions for controlling temperature conditions during casting production (mold technology, shakeout, and solidification of castings) through the parameterization and construction of a closed heat recovery system from the sand. • Significantly improved large-scale plate castings, such as ladle plates and flat weights (product innovation). The outcomes of the project include a significant reduction in annual CO2 emissions, a decrease in annual electricity consumption, and an increase in annual revenue and net operating profits. The company anticipates a substantial reduction in productionrelated waste, either through processing, recovery, or prevention of waste generation.