8/6/2019 Dray Cast Case Study

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CASE STUDY

Customer:

Draycast Foundries Ltd

One of the biggest considerations for industry today,when specifying new plant and equipment, is economy.Rapidly rising fuel prices have meant that companieshave to significantly reduce their energy consumption

n order to remain competitive, and the case wasno different for Draycast Foundries Ltd (Draycast) whenan influx of work meant they would need to order newmetal melting furnaces.

Located in Chesham, Buckinghamshire, Draycast startedn 1964 with two people and has developed into a wellespected foundry, operating from a purpose built facility,

and specialising in precision sand casting. Making useof the most up to date technologies available hasenabled Draycast to turn out consistently high qualitywork, earning the respect of customers all over Europe.

Discussions with Morgan Molten Metal SystemsMorganMMS) about possible ways to reduce running

costs created interest in the new MorganMMSRecuperative Furnace, particularly with potential fundingavailable through the Carbon Trust to finance thepurchase of energy efficient capital equipment. Thisenables the foundry to fund the initial outlay with annterest free loan, repayable over four years from theenergy savings made as a result of the furnacesmproved efficiency.

A visit to Draycast allowed MorganMMS to introduce theurnace, along with its advantages, and give an overviewof the Carbon Trust schemes and all they could offer inhe way of finance. Following this, Draycast Foundriesmade an application to purchase three, Size 2 gasecuperative furnaces. Throughout the process,

MorganMMS was always a phone call away, providing allhe information needed to back up the application,ncluding a full energy use spreadsheet, illustrating theavings which would be made.

The recuperative furnace itself builds on the success ofMorganMMS high efficiency gas fired bale out furnaces,ncorporating gas radiant panels and an insulationpackage which ensures more heat is directed where itsneeded, and not lost through the casing. This, coupledwith the high velocity gas burner used, means thecrucible is heated very evenly from top to bottom, servingo increase crucible life substantially. During evaluation,7 to 8 months crucible life was experienced ineach of the 3 Recuperative units, an increase of 2o 3 months over their older, non MorganMMS gasired furnaces.

The low NOx burner is fed with air preheated by therecuperator using waste exhaust gases, reducingexhaust gas temperatures and recapturing energy whwould otherwise be lost. Typically a minimum energysaving of 30% can be expected over a similar non-recperative furnace. The combination of the recuperator high velocity burner, fed by an inverter drivenregenerative blower, means there are no mechanicallinkages involved, making for a much more robust andcompact design.

By utilising this technology, MorganMMS has created furnace which not only offers a significant energy savin operation, but with very low noise output and lowcasing temperatures, provides a much more comfortaworking environment.

And its environmentally friendly too! As a responsiblecompany, MorganMMS recognises the impending intrduction of legislation governing emissions, and has a NOx solution in place, keeping within a target of 125pCO levels are lower too, and with more even heating

the crucible metal losses have been reduced, saving ocostly waste disposal.

According to Draycast Foundries manager Steven NaDraycast have only been able to maintain theirexcellent customer service in the face of increasinbusiness, through the installation of the threeMorganMMS units.

For details of the loans available from the Carbon Trust, vi

http://www.carbontrust.co.uk/energy/takingaction/loans.htm

The new

MorganMMS

Recuperative B

Out Furnace in

operation atDraycast

Foundries Ltd

Visit our web site for details on recuperative crucible furnaces: www.morganmms.com