TECH TALK
Using Artificial Intelligence ( AI ) to Reduce Scrap and Energy Usage in the Casting Process
Greenhouse gas ( GHG ) emission reduction requirements are found at the state and country level in most developed countries . For example , in 2020 , China announced its goals to strive for carbon dioxide peaking before 2030 and achieve carbon neutrality before 2060 . 1 As major industrial emitters face increased scrutiny to reduce emissions , the focus on regulatory compliance will also extend downward to encompass large- and medium-sized enterprises .
By Stephen Cherlet , owner / founder – FarStar S . A . C . Consulting and Dr . Mo Abduali , CEO and Managing Partnert – IoTco
The use of castings is central to a significant portion of the industrial valve industry . Depending on the valve design / type , castings can be found in pressure boundary parts ( body , bonnet , body end ), wedges , and other key components . Foundries are major energy consumers . Studies 2 have shown typical steel arc metal casting , typical for valve and pump manufacturing , consumes approximately 20.7 million BTU / ton . Reducing scrap and improving yield , in general , would represent notable energy consumption reduction , and therefore GHG emissions , where renewable energy is not being used in the steel-making process .
The automotive industry can serve as a guide . Predictive quality and energy reduction applications for high-pressure casting have been implemented in the automotive industry ( using the Predictronics PDX platform ). In this application , the software incorporates process data from the high-pressure casting process , including pressures , temperatures , cycle time , and other variables .
INVESTMENT CASTING FEINGUSS
MICROFUSIONE
A multivariate machine learning ( ML ) model is used to detect departures from the normal process conditions and provide insight into the factors contributing to the undesirable quality . Early detection allows the automotive part to be scrapped early in the process , so a re-melt can occur , which is much more cost-effective than scrapping the part at a later stage .
Process adjustments are recommended based on the key contributing factors affecting quality . This allows future runs to have better quality and fewer defects , such as porosity . An overall reduction in
APPROVALS
API-20A
Monthly capacity : 200 Tones / month . In house CNC machining facilities with CNC Turning / VTL / VMC / HMC machines
Investment castings upto 150 kg weight / pc
INDUSTRIES SERVED
INDUSTRIAL VALVES
ISO 9001:2015 by TUVNORD INDUSTRIAL PROCESS PUMPS
ISO 14001:2015 by TUVNORD POWER PLANT EQUIPMENT
ISO 45001:2018 by TUVNORD
GENERAL ENGINEERING
PED 2014 / 68 / EU by TUVNORD AD 2000-Merkblatt W0 by TUVNORD LLoyds Marine Approval NORSOK M-650 Approval NORSOK CK-3MCUN DNV / GL Marine Approval IBR CERTIFICATE American Bureau of Shipping Marine Approval Bureau VERITAS MARINE Approval
MATERIALS CASTED
Stainless steels , Duplex Stainless Steel , Nickel based alloys , Carbon steels , Cobalt based alloys
Tilara Gate , Shapar Industrial Area , Rajkot-Gondal NH-27 , D i s t . R a j k o t - 3 6 0 0 2 4 . G u j a r a t - I N D I A Tel . : + 91-2827-252160 , 252161 Fax : + 91-2827-252562 Email : info @ rajantechcast . com
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26 Valve World Americas | April 2024 • www . valve-world-americas . net