FOUNDRY PROJECT PLANNING - SOME PIT FALLS

Ziauddin

Avinash Joshi

Advisor (Tech & Projects)

Amtek Foundry,
Email: ziauddin@amtek.com,
zia_45@rediffmail.com

Sr.Vice President,
Engineering, Amtek Foundry
Email: avinash.joshi@amtek.com

ABSTRACT
The paper deals with some pitfalls in project planning and not in project management, which prevents a
foundry from achieving its planned capacity in scheduled time. This is mainly due to non availability of
material handling equipments and imbalances between different production processes. The paper includes
description of some production bottlenecks observed by the authors in the foundries where they served or in
some other foundries.

1. INTRODUCTION
In recent past many foundries in India have modernized
their operation by installing new machinery and
equipments. However, it has been observed that most of
the foundries take longer than the planned time to reach
the installed capacity level and financial targets. Most of
the foundries do careful planning while selecting molding
line, sand plant and melting furnace but same attention is
not given for core shop, fettling shop and infrastructure
needs of the foundry like material handling equipments for
raw materials and castings etc. for smooth flow of inputs,
outputs and waste. Capacity imbalance between different
production activities is also a major reason for not
achieving desired level of production. This paper attempts
to highlight some of the issues which if not taken care of
during planning stage, ultimately results in delay in
achieving installed capacity level.
For making this paper data oriented, an imaginary foundry
has been considered with high pressure molding line
producing grey iron automotive castings. The basic
parameters of imaginary foundry are given in Annexure I.

2.PROVISION FOR SPACE AND HANDLING

SYSTEM FOR RAW MATERIALS
Adequate space at right locations should be provided for
storage of raw materials in the foundry layout. Storage and
handling of some important materials is discussed below:-

2.1 Raw Sand

Raw sand is required in the foundry for core making and for
addition in molding sand. In this paper it has been assumed
that

new or raw sand is not added in green sand as its

requirement is being taken care of by ingress of core sand
at shake out.
For approximately 3000 tons per month gross production
(Annexure-II, 6), new sand requirement for core shop will be
2022 tons per month (Annexure-III,6).
For the imaginary foundry of this paper only cold box
process has been envisaged. Therefore, the raw sand
should be in washed condition containing less than 0.2%
AFS clay. Depending on the geographical location of the
foundry, the source of sand may be from Allahabad, Gudur,
Mangalore, Rajmahal etc. Most of the suppliers give washed
sand which may be dried in foundry. If sand supplier dries
sand in rotary or fluidized bed dryer it will be satisfactory for
cold box process with no moisture. But most of the
suppliers do not have any facility for sand drying and supply
sun dried sand which contains varying amount of
moisture. If foundry has not planned for sand drying
facility, production of core becomes a bottleneck. Stock
should be maintained for the period during which annual
maintenance of dryer is carried out .
There are many eventualities which may disrupt sand
supply; like stoppage of mining operation during monsoon
due to flooding of mines, reduced mining operation during
hot summer etc. Therefore, foundry has to store reasonable
quantity of sand for the above eventualities. If 15 days stock
is assumed then storage capacity of approximately 1000
tons is to be created. Every foundry should decide about
safe stock level considering lead time etc.
Washed sand may be stored in pits where from it may be
fed to the dryer and ultimately stored in hoppers for supply
to mixers of core making machines. Storage of sand in pits

suffers from disadvantage that FIFO cannot be followed.

Sand which remains at the bottom accumulates more clay
as water seeps from top wet sand to bottom. In a situation
when sand stock is low, production of core may suffer due
to high clay content of the sand. A solution to this problem
could be to have two pits for sand storage using one for first
15 days and the other for the next 15 days of the month. If
sand is procured in washed and dried condition, duly
packed in bags, there should be enough space for storing
bags. In both the cases the sand has to be filled in hoppers
for feeding to mixers of cold box machines. This can be
done by either by dense phase pneumatic conveying
system or by conveyor belts. Pneumatic conveying should
be used only if the conveying distance is not more than 50
meters, as it has been found to generate fines.

It has been noticed that many foundries receive Ferro alloys

and carburizers in stores and then issue daily requirement
to melt shop which is generally carted by tractor trolleys.
Authors of this paper are of the opinion that Ferro-alloys
should be directly unloaded in melt shop as consumption of
these materials are regulated by chemistry of liquid metal
which is done for each heat. Control on consumption of
these materials should be delegated to melt shop incharge.
Material like copper and tin may be kept in stores and then
issued as per requirement as there is chance of pilferage
from melt shop.

3. CAPACITY IMBALANCE BETWEEN

DIFFERENT PRODUCTION PROCESSES.
For the given throughput, all sections, including sub
sections, of the foundry plant need be carefully balanced.
Adequacy of service functions must also be considered.

2.2 Bentonite
The quantity of bentonite required per day is 8.6(AnnexureIV,15) tons or about 215 Tons / month. Sources of good
quality of bentonite in India are in Kutch area. Depending on
location of foundry, bentonite may have to travel large
distance to reach foundry. In order to save on freight most of
the time it is procured in 40 Ton trawler. A foundry during its
planning stage should have adequate space for storage of
bentonite. Ideally this space should be as near to sand plant
as possible. But generally, it is not available and hence a
separate godown is required. For daily requirement it is
carried to sand plant with the help of tractor trolleys and
then filled into hopper. This results in multiple handling and
cost.

3.1 Core Shop Production Capacity And

Imbalance With Molding Line
For a jobbing foundry where product mix is not exactly
known, it is difficult to
balance core production with that
of molding line requirement. In the imaginary foundry of this
paper, only cold box process for core making has been
envisaged. The actual cycle time for making one core or one
set of core on the same machine should be considered to
arrive at the capacity of the core shooter. In our case the
same is 90 seconds say and the cycle time of molding line is
36 sec (@ 100 molds/ hour). Assuming that one core
shooter gives cores for one mould, with 2 core shooters we
get 2 sets of cores per 90 sec; i.e. we can cater to 2
moulds/90 sec. Thus we get 1 set of cores/ 45 sec and
hence need 3 core shooters. If cores are produced on
different machines with different cycle time and are then
assembled to make one set for one casting then production
from each machine and assembly time need be balanced
with the molding line speed. After taking out core from
machine it requires further processing like de-finning,
assembly, washing, drying and cooling. Efforts should be
made to make all these operations as one line one piece
flow and balanced at all these stages.

2.3 Coal Dust Or Coal Dust Substitute Material

The quantity required per day is about 3 Tons / day
(Annexure- IV, 16) Problem of storage and subsequent
supply to sand plant is similar to as described above for
bentonite.
To reduce multiple handling, both bentonite and coal dust
may be pneumatically conveyed from bulk storage godown
to sand plant hopper. Pneumatic conveying system of both
these material is trouble free as these are free flowing
materials, do not abrade pneumatic conveying pipes, and
conveying distance is not a constraint.

After application of water base coating or wash, the cores

are to be dried in oven. Generally two methods of feeding
cores into the oven are followed. In one process every core
after application of wash is kept on oven conveyor which
carries it through different temperature zones of the oven
and when core finally emerges from the oven it is in dry
condition but slightly above the room temperature. The
cores are then picked up from the oven conveyor, kept on
trolleys which are then carried to molding line, as and when
required.

2.4 Melt Shop Raw Materials

Raw material required in melt shop is given in Annexure- V.
Monthly requirement of steel plus pig iron is 2657 Tons
(Annnexure-V,5,6) which is 106 Tons per day. This quantity
of material need to be unloaded by electromagnet of
overhead crane in general shift. Additionally, overhead
crane with electromagnet is also required for charge
preparation.
Therefore, number of overhead cranes with electromagnet
need to be carefully decided otherwise it will ultimately
results in delay in liquid metal output from the furnace. In
case foundry decides to use cast iron borings, it should be
ensured that it is free from dust , other contamination and
oil , otherwise it reduces the effective melting capacity.

In some other foundries, cores are washed and kept on

trolley. Once the trolley is full, the entire trolley is passed
through the oven. The same trolley is then taken to mold
shop.

A foundry may follow any of the above two processes,

keeping in mind that cold box cores, after application of
wash should be subjected to drying, as soon as possible.

shake out frequently which results in stoppage of

production. Some observations in different foundries are
described below:-

The number of trolleys required can be worked out,

depending on core requirement and turn around time.
Sufficient space for movement and parking of trolleys should
be provided for in the core shop.

3.3.1 Case-1 In one foundry there was about 30m long

and about 6m wide space available in front of shake out.
Castings were picked up, with the help of pneumatic hoist
which was mounted on an overhead single girder crane
covering shake out and the space mentioned above. After
picking up casting from the shake out deck, the crane was
suppose to travel up to the farthest end of the 30m long
space, keep the casting on floor and come back to pick
up the next casting. It was planned that casting will be
picked up by another hoist and placed on tractor trolley for
transportation to fettling shop. After unloading the casting in
fettling shop with the help of another crane, tractor trolley
was required to come back and repeat the operation. In
practice, there were many delays with the result that
castings were kept in heap on floor, often resulting in
damage or broken casting as castings used to roll over each
other and fall on floor. In this foundry molding line has to be
frequently stopped to clear the castings from shake out
deck or from the floor for creating space for new castings.
3.3.2 Case-2 In another foundry with high pressure
molding line, with installed molding rate of 100 molds per
hour, it was observed that over the shake out a mono rail
type of arrangement was provided which was suppose to
pick up casting from the shake by hoist and travel about
30m to adjacent fettling shop, keep casting on floor and
come back to pick up next casting. Obviously, this resulted
in casting accumulation on shake out deck which ultimately
caused stoppage of production.
3.3.3 Case-3 In another foundry, very good arrangement
was made for shifting casting from shake out to fettling shop
by providing a casting pick up manipulator and an overhead
casting conveyor. Casting was picked up by manipulator
and kept on the pan, fixed on the hook of the conveyor
which carried it smoothly to fettling shop. In fettling shop
conveyor lowered to about 1.5 m height. For unloading the
casting from conveyor, there was a mechanical
arrangement for pulling the hook of the conveyor which tilted
the pan to make casting fall on the floor, damaging the floor
or casting or both. Since the mechanical arrangement of
unloading the casting was fixed in one position, the next
casting has to fall in the same position, as earlier one. To
prevent this from happening, casting were dragged on floor,
manually with the help of steel rods, suitably bent at the
end. Because this arrangement was very unsatisfactory,
arrangement was made to lift the casting from conveyor pan
and keep it on a slat conveyor which carried the castings to
shot blasting machine. Slat conveyor was again found to be
unsatisfactory as it used to breakdown frequently due to
metal chips, flashes, vent pins and black sand entering
between slats and bending and distorting it. It was also not
considered that the castings would come with the gating
system attached to it and no provision was made for its
removal and transportation. Slat conveyors were removed
within three months after installation and replaced with vibro
conveyors. However, the whole exercise took about one
year.

3.2 Imbalance Between Molding Line And Melt

Shop
Imbalance here obviously means shortage of liquid metal
resulting in stoppage of molding line. This happens in many
foundries in spite of melting capacity of furnace, as
envisaged during project stage, appears to be correct. For
example, in a foundry a medium frequency furnace of 8 ton
capacity with 5000 KW power input was procured to get a
melting rate of about 10.2 Ton/Hr. at 1500C to satisfy
molding line demand. This was also demonstrated by
furnace supplier with hot lining, clean and dense charge
material, no heel, filling one third furnace quickly followed by
charging to match melting speed and closed cover during
most of the melting time. This means that an eight ton heat
should be ready in about 47.2 minutes. But during normal
production it was found to take about one hour to prepare a
8 Ton heat, ready for pouring. This was because of
following reasons:-

i) Condition Of Charge Material:Quality of heavy melting scrap (HMS) was not consistent
and at times rusted. Foundry returns i.e. gating system and
rejected castings were with varying amount of sand sticking
to it. Further, packing density of gating system was too low.

ii)Charging Method Of Furnace:Charging by bottom opening basket was not keeping pace
with melting rate. Charging by vibro charger can improve
the situation.

iii)Time Taken For Deslaging:The amount of slag formed varied from heat to heat and
slag removal time was operator dependent.

iv)Time Taken For Chemical Analysis:This time gets added in melting cycle because
dispensation of liquid metal can start only after ensuring
right chemistry and liquid metal at right temperature.
In a jobbing foundry liquid metal demand at molding will
keep varying depending upon the casting being produced.
To avoid stoppage of molding due to non availability of liquid
metal, a buffer stock of liquid metal may be created. This
may be done by installing a holding furnace of suitable
capacity. Some fluctuation in metal demand may also be
taken care of by installing an automatic pouring furnace
(popularly known as press pour).

3.3 Production Stoppage Due To Delays At

Shake Out :It has been observed that, at times, facilities provided at the
shake out for the removal of casting are not able to cope
with the speed at which castings are coming on the shake
out deck. The operator under these circumstances stops the

3.6 Production Delays Due To Material Jam In

Basement:-

Casting transport from shake out to fettling area is generally

done with the help of bins, tractor trolleys or conveyor. After
transporting, castings need to be kept for cooling before any
further operation like de-coring or shot blasting. Therefore, if
sufficient number of tractor trolleys or bins is not provided,
accounting for cooling and emptying out time it becomes a
cause of production delay. Similarly, casting conveyor
length should be long enough to allow the castings to cool
for subsequent operation.

The layout of high pressure molding line and sand plant, as

envisaged in this paper, will have underground tunnels
where belt conveyors will be running for carrying sand from
stations like vent drilling, pouring cup cutting, excess sand
cutting, molding machine and shake out. On return sand belt
conveyor, one or two over band magnetic separator (OBMS)
are provided. Additionally, a magnetic pulley is also
provided at a suitable location. Metallic materials collected
by these equipments, in addition to spilled sand, needs to
be regularly removed. It has been observed that in many
sand plants the under ground tunnels are so narrow that it
becomes very difficult to access, collect and remove these
materials. Over and above atmosphere in the tunnel is hot,
humid and suffocating in absence of ventilating arrangement
where workers are not ready to work. This results in material
accumulation in the basement and situation becomes so
bad that plant has to be stopped to remove accumulated
material.

3.4 Imbalance Between Production And

Fettling Operations:Casting production on high pressure molding line
may be regarded as continuous process where as
casting transportation by bins/trolleys and
subsequent operation like shot blasting by hanger type
machine is batch process. It requires careful planning to
match these two types of processes. Fettling, after shot
blasting should be made continuous process by providing
suitable facilities like roller conveyor and by providing tools
like grinding machine, chisel, hammer etc and by defining
operations to be done on a casting as it moves on different
stations on the roller conveyor.

It is therefore, suggested the tunnels should be of ample

width so that any belt conveyor, OBMS or equipment like
vibro feeder below shake out should be accessible from
both sides. The cut outs provided in the floor at 00 level
should also be big enough for easy movement of basket
containing waste material.

Customers do not accept castings with grinding marks

which gives glossy appearance after painting. Therefore,
castings are shot blasted again with shorter cycle time.
Therefore, shot blasting capacity should be two times that of
production capacity.

A still better but costly option is to construct a basement,

instead of tunnels with sufficient head room for movement of
material handling equipment like fork lift etc. This requires
landscaping of site from civil construction stage thus making
foundry at a level above ground floor. In the opinion of the
authors, this option is the best, though costly but it will pay
off in the long run.

Casting painting facility should match with the fettling

throughput. Care should be taken to account for reduced
throughput due to longer time taken for paint drying during
winter and rainy season.

3.5 Dispatch Delays:Project team should remember that a foundry gets paid for
what it dispatches and not what it produces. It is therefore,
necessary to allocate adequate area in the foundry layout
for handling, packing (if required) and dispatch. This area
should be furnished with material handling equipments like
hoist, fork lift, pallet lifter etc. It has been observed that in
many foundries such facilities are not provided for, with the
result that dispatch is delayed even though castings are
available in go down. This is becoming increasingly
important because customers are demanding just in time
delivery of casting at their end. There are cases, where
customer has forced the foundry to establish a go down
near their premises, maintain a minimum level of inventory
and deliver daily requirement at a given time. Foundries
have done this at their own expenses, cutting in their profit
margin.

4. LOGISTICS MANAGEMENT
Handling and storage of some important raw materials have
been already discussed in section 2 of this paper. As shown
in Annexure-VI, there is about 207 tons of incoming raw
materials every. This does not include materials like Diesel
oil (for sand drying, ladle heating, trough heating of pouring
furnace and wash drying oven), shots for shot blasting
machine, paint for casting and core washes. On an average
about 114 tons of casting need to be dispatched everyday.
All materials which do not go to the customers and are not
converted to gas will go out of the factory, sooner or latter,
in some form or the other. Therefore, on an average about
90 tons of sand and bentonite needs to be disposed
everyday. The foundry should therefore, be equipped for
receiving and dispatching/disposing about 400 tons of
material everyday.

In case of imaginary foundry of this paper, 114 Ton (Ref.

Annexure-II,9) of casting must be dispatched every day.
This requires loading of 12-13 trucks of 9 tons each, in
general shift of 8 hours. This obviously can not be done by
manual loading.

At all work stations and transfer points, quantitative study of

Input/Output/Byproduct must be done thoroughly and
necessary handling facilities should be provided. It is often
experienced that for many of these activities analysis is not
done, provisions are inadequately made and are just left to
the discretion of the workers.

technology employed. Quality of work force plays a vital role

in attaining project deadlines. A carefully determined ratio of
permanent v/s contract employees, local v/s out side work
force, in light of the competency mapping plays a key role.
Often it is observed that management itself is not geared up
to handle such a situation and results in poorly manned,
poorly skilled work force. A strategic decision with clarity of
Business Cycles is a key to decide on HRD policy.

5. DEVELOPMENT OF COMPONENTIt has been noticed that casting development at times takes
unduly long time. Even after sample casting is approved, its
production at rated rate and in required number does not
happen. All this eventually results in delay in achieving
planned capacity. Some reasons for this are discussed
below:-

5.1 Feasibility:

7. BALANCING OF THE LINE FOR GIVEN

THROUGHPUT-

Components with poorly conceived feasibility and process

design often take too long time to take off or some time
never take off in the real sense.
List begins with wrongly conceived casting weight, core
weight, yield as the most common, followed with wrongly
conceived parting line of mould and cores, tolerances,
critical characteristics, painting, packing etc. Most of the
times adequate quantity of tools for the given volume and
tool material is never considered. Much of the credit to this
could be attributed to unnecessary pressures from
marketing or by the customers. It is the responsibility of the
Development Head to plead the case with due justifications.

The plant capacity is often mistaken with the capacity of

molding line. As already stated above, if not carefully
conceived and balanced at the project stage itself,
imbalances are very difficult and challenging to be
corrected at the take off stage, also they result in shift of
focus from casting development and production to
debugging project pitfalls. With experience, the authors
would like to suggest the following ratio for capacity of
different areas, as guideline

5.2 Process Design:

Poorly conceived Process Flow for the given volume,
inadequate FMEA as a result of poor process knowledge
reflects in to poor Mould Scheme and Tool Design. This
ultimately results in delays, inconsistent quality, in adequate
tools and frequent tool corrections.

Mould Line : Melt Shop : Core Shop : Shot Blast : Fettling

Shop

5.3 Problem Solving:

8. CONCLUSIONS

It is observed that at times incorrect root cause analysis

results in the actions on the tool to compensate for the
process variations. This results in inconsistent products with
never ending exercise of tool corrections and frequent
delays in availability of tools.

: 1.2

1.4

2.5

: 1.5

It has been observed that some foundries take unduly long

time to achieve its planned production capacity level in spite
of being equipped with good molding line, sand plant and
melting furnaces. The main equipments fail to give rated out
put because supporting equipments provided are
inadequate and do not match with the requirements of main
equipments. These inadequacies have been highlighted
starting from receipt and storage of raw materials to the
dispatch of casting including disposal of waste material

6 HUMAN RESOURCE DEVELOPMENT(HRD)

HRD itself is a topic of separate deliberation. However,
Policy and Strategy must be worked out considering location
of the project, history of the company and class of

.
************
Annexures I to VI follow on subsequent pages

ANNEXURE I
BASIC PARAMETERS OF IMAGINARY FOUNDRY
S. No
1
1.1
1.2
1.3

Parameters / Factors
General
Type of Foundry
Metal Cast
Type of Casting

Unit
-----

Details
-Jobbing
Grey Iron
Automotive

1.4
1.5
1.6

Hours per shift

Hours per day
Working hours per day

Hr
Hr
Hr

8
24
21.5

1.7

Working days per year

No.

300

2
2.1
2.2
2.3

Molding Line
High pressure box molding line
Box size
Molding speed

-mm
Molds/Hr

-1000x800x300/300
100

3
3.1
3.2
3.3
3.4
3.5
3.6

Sand Plant
Capacity
Mixer
Mixing cycle
Cooler
Online controller
Dust extraction system

Tons / Hr
-sec
----

4
4.1

Melt Shop
Type of furnace

--

4.2

Pouring

--

4.3

Inoculation

--

5
5.1
5.2

Core Shop
Core making process
Core making machine

---

5.3

Core washing and drying

--

5.4

Type of wash

--

Remarks
---Cored castings like
gear box housing
,differential housing,
clutch housing etc.
and non-cored
casting like fly wheel,
brake drum etc.
--In every shift of 8
hrs., 30 min meal
break and 2 breaks
of 10 min each
--

-----

80
Intensive
110-130
-Compactibility
Two nos. connected to
cooler plus other areas
and shakeout plus other
areas.

-------

Medium frequency
coreless induction
Automatic pouring
furnace
In stream

--

Cold box
Horizontally and vertically
parted machines as
required
Fuel fired wash drying
oven
Water base

---

---

---

ANNEXURE I (Contd.)
S. No
6
6.1
6.2

Parameters / Factors
Fettling Shop
Shot blasting machine
Fettling

Unit
---

6.3

Painting

--

6.4

Dispatch

--

7
7.1
7.2

Quality control
Chemical analysis
Sand testing

---

Details

Remarks

Hanger type
Manual by swing frame
and hand held grinders.
Spray painting on moving
hangers.
By open trucks, loading
manual and with the help
of pneumatic hoist.

---

Emission spectrometer
Set of conventional sand
testing equipments.

---

---

ANNEXURE II
INSTALLED CAPACITY OF FOUNDRY
S. No
1
2
3

Parameters / Factors
Average Casting weight per box
Working hours per day
Average efficiency of molding
line

Unit
Kg
Hrs
Molds / Hr

Details
70
21.5
80

4
5
6
7
8

Molds poured per hour

Casting production per day
Gross production per month
Gross production per year
Dispatch per month

Molds / Hr
Ton
Ton
Ton
Ton

80
120.4
3010
36120
2859

Dispatch per day

Ton

114

Remarks
-Ref. Annexure-I,1.6
Accounting for
inefficiencies like
delay on molding
lines due to pattern
change, core
settings, broken
molds and delay in
pouring.
-80x70x21.5
120.4x25
Assume 5 % foundry
rejection

ANNEXURE III
NEW SAND REQUIREMENT FOR CORE SHOP
S. No
1
2
3
4
5
6

7
8
9
10

Parameters / Factors

Unit

Details

Gross production per month

Cored items
Gross production of cored items
per month
Average casting weight to core
weight ratio
Core required per month
Raw sand required per month

Ton
%
Ton

3010
80
2408

Ref. Annexure- II,6

Of gross production
---

Ratio

1:0.8

--

Ton
Ton

1926
2022

Ton
Ton

81
20.22

-Assume 5% core
breakage plus sand
mix wastage.
1
1% of sand

Ton

18.2

0.9 % of sand

Ton

2.8

@ 2 cc per kg density
0.7 gm/cc

Raw sand required per day

Cold box resin required per
month
Cold box catalyst required per
month
TEA for cold box per month

Remarks

ANNEXURE IV
BENTONITE AND COAL DUST REQUIREMENT FOR MOLDING SAND
S. No

Unit

Details

Mould poured per day

No

1720

Molds produced per day

No

1772

Molds for non-cored castings

No

354

Sand in one pair of full molding

box(without cavity)

Kg

696

Average weight of casting(for

non cored and cored casting)
per box
Casting yield

Kg

70

70

Average weight of liquid metal

per box
Average weight of molding sand
per box for non core castings
Prepared molding sand required
per box for non-core castings

Kg

100

Assume same for

core and non core
castings
70/0.7

Kg

676

696-100/5

Kg

744

Tons

263

Assume 10% excess

sand (over box
flange)
744x354/1000

Tons

1418

7
8
9

10
11

Parameters / Factors

Molding sand per day for non

core castings
Molds for cored castings

Remarks
80 molds / Hr x21.5
Hrs / day
Assume 3 % mold
breakage
20% of mold
produced
Assume compacted
density of sand
1.45 gm/cm3
--

12

Average weight of molding sand

per box for cored castings

Kg

620

13

Prepared molding sand per day

for cored castings
Total quantity of molding sand
required per day
Quantity of bentonite required
per day

Ton

879

80% of molds
produced
696-100/5-70x0.8
(Ref. Annexure
III.4)
1418x620/1000

Ton

1142

263+879

Ton

8.6

Quantity of Coal dust substitute

required per day

Ton

2.9

14
15

16

Assume bentonite
addition @ 0.75 % of
molding sand
Assume addition @
0.25 % of molding
sand.

ANNEXURE V
MELT SHOP RAW MATERIALS
S. No

Parameters / Factors

Unit

Details

Gross production per month

Liquid metal required per month
Charge material required per
month
Charge ratio pig Iron : return :
steel scrap

Ton
Ton
Ton

3010
4300
4429

15:40:45

5
6
7

Steel scrap required per month

Pig iron required per month
Ferro-Silicon required per month

Ton
Ton
Ton

1993
664
59.8

CPC (calcined petroleum coke)

required per month

Ton

68.8

Ferro- Manganese

Ton

15.9

10
11

Ferro-Chrome
Inoculant required per month

Ton
Ton

-8.6

1
2
3
4

10

Remarks
Ref.Annexure-II,6
Yield-70%
Assume 3% melting loss
Return consists of gating system30%, foundry and customers
return (10%)
45% of 4429
15% of 4429.
Assumptions- Required bath Si2%,Si pick up from Fe-Si-60%. Si
in steel scrap-0.2%. Neglecting Si
available from pig iron., Fe-Si
required 30 Kg/ton steel scrap.
Assumption- C in steel scrap-0.2
%, bath C-3.3%, carbon pick up
from CPC-90% .Neglecting C
available from pig iron. CPC
required-34.5 Kg per ton steel
scrap.
Assumption Mn in steel scrap
0.2%, Mn pick up from Fe-Mn50%. Neglecting Mn from pig iron.
Assume 0.2% of liquid metal

ANNEXURE VI
MATERIAL MOVEMENT
S. No
Material
Incoming materials
A.

Unit

Details

1
2
3
4
5
6

Ton
Ton
Ton
Ton
Ton
Ton

81
8.6
2.9
80
27
6

Ref Annexure III, 6

Ref Annexure IV, 15
Ref Annexure IV, 16
Ref Annexure V, 5
Ref Annexure V, 6
Ref Annexure V, 7,8,9,11

Ton

1.65

Ref Annexure III, 8,9,10

Ton
Ton

207

B
1
2
3
4

Raw sand, per day

Bentonite, per day
Cold dust substitute , per day
Steel scrap per day
Pig Iron, per day
Fe-Si, CPC, Fe-Mn, Inoculant,
per day
Cold Box resin, catalyst , TEA,
per day
Total
Out going materials
Black Sand

Remarks

For material balance sum of these

materials should be almost equal
to total of raw sand , benonite and
coal dust substitute material.

Unusable material from dust

extraction system of sand plant
Broken cores and waste mixed
sand
Waste material from dust
extraction system of shot
blasting machines and other
areas of fettling shop
Slag from melt shop

Note:- Materials not accounted

i. Diesel for sand drying , ladle heating , pouring furnace trough heating and wash drying
oven
ii. Shots for Shot Blasting Machine
iii. Paint for castings
iv. Wash for cores

11