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ENERGY CONSUMPTION IN THE SYSTEM

Project and research leaders
Eva Troell Swerea IVF
Peter Naystrm Swerea Swecast
Lars Nyborg Chalmers
Magnus Widfeldt Swerea IVF (red)

Content
1. Executive
summary..................................................................
................................. 3
2.
Background ..............................................................
................................................. 4
3.
Objective ...............................................................
..................................................... 5
4. Project
realization..............................................................
....................................... 5
4.1 Sustainable heat treatment
factories................................................................
............... 5
4.2 Sustainable casting
production...............................................................
........................ 7
4.3 Sustainable machine shops Fluids and Waste
Management ..................................... 11
5. Results and
deliverables ............................................................
............................. 14
6. Dissemination and
publications.............................................................
................ 15
6.1 Knowledge and results
dissemination............................................................
.............. 15
6.2
Publications.............................................................
..................................................... 16
6.3 Collaboration to other
projects.................................................................
.................... 16
7. Conclusions and future
research ................................................................
........... 17
8. Participating
parties .................................................................
.............................. 17
FFI in short
FFI is a partnership between the Swedish government and automotive
industry for joint funding of research,
innovation and development concentrating on Climate & Environment and
Safety. FFI has R&D activities worth
approx. 100 million per year, of which half is governmental funding. The
background to the investment is that
development within road transportation and Swedish automotive industry
has big impact for growth. FFI will
contribute to the following main goals: Reducing the environmental impact
of transport, reducing the number
killed and injured in traffic and Strengthening international
competitiveness. Currently there are five collaboration

programs: Vehicle Development, Transport Efficiency, Vehicle and Traffic

Safety, Energy & Environment
and Sustainable Production Technology.
For more information: www.vinnova.se/ffi
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1. Executive summary
The project Sustainable Production Processes was executed from 2009 to
2012, within
the FFI partnership between the Swedish government and the automotive
industry, specifically
within the collaboration program Sustainable Production Technology,
Vinnova project
no 2009-00315. Three specific work packages have been executed:
Work packages:
1. Sustainable
2. Sustainable
3. Sustainable

Work package leaders:

heat treatment factories Eva Troell, Swerea IVF
casting production Peter Naystrm, Swerea SWECAST
machine shops Lars Nyborg, Chalmers

Project leader was initially Tero Stjernstoft, former Swerea IVF now
Vinnova, and then
Magnus Widfeldt, Swerea IVF.
Work package 1: Sustainable heat treatment factories
Objective: To minimise energy consumption and the use of chemicals and
consumables
during heat treatment, specifically during cleaning processes.
Results: Key-index values for different heat treatment processes. The
energy needed per
tonne heat treated materials is particularly related to the percentage
used of the furnace cavity.
The case hardening process needed three times more energy per tonne if
the owen was
filled to 10% compared to a fully loaded owen. Heat treatment neeeds
clean material surfaces,
and environmentally adapted cleaning is a key process.
Laboratory processes as well as procedures that can be suitable for
application in connection
to the heat treatment workshop have been evaluated regarding surface
cleanliness after
washing, prior the heat treatment process. Methods for evaluation and
measurement of surface
cleanliness have been examined. There is still need for research
regarding how clean a
surface needs to be depending on heat treatment process to be applied,
e.g. nitriding or case
carburizing. Knowledge transfer has taken place by the Swedish Heat
Treatment Centre
(Vrmebehandlingscentrum) and Vrmebehandlingsforum.
Work package 2: Sustainable casting production
Objective: To develop more cost-efficient casting production and make
progress towards
the waste-free foundry by reducing or eliminating the amount of
foundry-generated
waste, using waste as a resource in other processes, and reducing the
need for virgin materials
in the production of castings.

Results: Increased internal reuse of sand is possible due to improved

cleaning methods.
Bentonite-bound green sand containing coal dust has been recycled for
production of cores.
Two different recycling methods have been tested mechanical and
thermal. The results
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