Attention to sustainability, as demonstrated by the 14001 environmental certification and ISO 50001 energy certification, can be seen from the actions that Fonderie di Montorso consistently implements to tackle environmental impact, workplace quality and energy savings. Especially for the latter, 2019 was packed with interesting measures with very encouraging and significant results.
When developing any project, it is essential to collect data and assess the results. Therefore, we have extended the system of energy meters with dedicated consumption monitoring and analysis software to both our plants. This provides a detailed snapshot of the company’s energy consumption, allowing us to identify the areas in which to take action and assess the results achieved with the actions already taken.
The most significant project at the Montorso plant in 2019 consisted of replacing the extraction filters serving the finishing and deburring shops.
Sized to ensure optimal air quality in the shops that have grown, the new filters are more power, but as a result also more energy-hungry. Precisely for this reason, choosing latest generation systems with inverter technology has made it possible to limit energy consumption, saving 75,000 kWh in a year. This brings not just economic but also environmental benefits because the kWh saved correspond to approximately 30 tons of CO2 not released into the atmosphere.
The numerous measures taken on compressed air consumption have given excellent results.
In general, being a secondary energy vector, compressed air is not normally subject to energy diagnosis even though it is used in many sectors and has a significant impact on energy consumption. Yet, sizing the compressed air line correctly and maintaining it carefully can save many kWh of electric energy per year.
By analysing the compressed air pressure used in the machines we have reduced the overall working pressure by one bar, giving a 10% reduction of the consumption needed to produce the compressed air, equivalent to 500,000 kWh per year (200 tons of CO2)
An in-house study of the ideal configuration for a new sandblaster installed in the finishing shop has led to an energy saving of 96,000 kWh per year (40 tons of CO2)
A further saving of 175,000 kWh is the result of modifying the quenching system that serves the cupola furnace, which has a compressed air system that works 24 hours a day, 365 days a year. Adopting PLC control for the cleaning system has made it possible to differentiate the blowing time for actual treatment from that for machine self-cleaning.
These are the most significant initiatives launched in 2019, and we have many others in the pipeline…we are happy to be able to contribute to environmental protection.