An Innovation into Reuse of Risers for Energy Conservation in Metal Casting

Abstract

In conventional casting, the riser is separated from the casting and remelted for further use. If the riser can be configured to house a product, it can save energy for separately melting in making that product. In present work the separated riser is used as a raw material for another product without subjecting it to melting. A green sand mould consisting of a cubical pattern and LM 4 grade aluminium metal were used for the experiment. The riser used was designed to embody a cylindrical rod of 3.5 cm diameter. For the product given out by the riser used in this research energy saving to the tune of 23.5 % could be achieved. If this is extended to annual production of 98,593,122 tons of castings in the world, the cumulative energy savings amount to 17840 GWh, minimizing 7671200000 tons of CO2per year. Hence such innovations can be explored more deeply for industrial implementation.