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For
improving operations, everyone would like to know what
others have achieved, how his figures compare with theirs
and what is the scope for improving one's performance. |
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We
are giving below some benchmarks in different fields of
foundry. These are based on the information we have
at present. There may be some who have achieved better
results than this. We request them to inform us their
figures and we will update our records accordingly. |
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Members
/ visitors to this website are requested to share their
knowledge with us and based on their practical experience,
give us benchmarking figures in other areas of foundry
operations which are not mentioned below: |
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Medium
frequency induction furnace : |
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Power
Consumption
|
750
KWH / MT ( for Steel ) |
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650
KWH / MT ( for C. I.) |
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Power
factor |
0.98 |
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No.
of heats / lining for C.I. |
600
( 3 shift operation ) |
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500
( 2 shift operation ) |
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Cupola
Operation: |
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Melting
Rate |
:
24" I.D. - 2.5 T / Hr
: 30" I.D. - 3.5 T / Hr
: 36" I.D. - 5.0 T / Hr
: 42" I.D. - 7.0 T / Hr |
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Melting
Losses |
6
% of metal charged. |
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Silicon
and Manganese
Losses element |
8
% of the charged. |
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Refractory
Consumption |
7
Kgs / Ton of metal. |
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Steel
addition cold blast cupola |
50
% of the charged. |
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Temperature
of exhaust gases |
200
deg. Cent. |
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Foundry
Rejection due to
foundry causes |
2
% |
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Melting
loss in Aluminium |
1.5
% ( if Ingots are used ) |
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4
% ( if Ingots + Scrap are used ) |
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Melting
loss in G.M. / Bronzes |
1
% for solid material. |
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6
% for Turning / Scrap Boring |
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Machining
Allowance on
Centrifugal Castings |
2.2
mm ( on Bore ) |
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(Cylinder
liners for automobiles) |
1.5
mm ( on O.D. ) |
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Consumption
of Fe-Si-Mg
Alloy (S. G. Iron) |
1.3
%
0.9 % [ with high Ca ( 2.5 %).
high Ce ( 2.5 %)] |
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Note
: Following experts have contributed to the above data. |
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Late
D. V. Paranjpe, Mr. S. B. Pathak, Mrs. S. S. Karkhanis,
Mr. R. D. Chavan. |
