Casting is one of the oldest, most challenging and energy intensive manufacturing processes. A typical modern casting process contains six different stages, which are classified as melting, alloying, moulding, pouring, solidification and finishing respectively. At each stage, high level and precision of process control is required. The energy efficiency of casting process can be improved by using novel alterations, such as the Constrained Rapid Induction Melting Single Shot Up-casting process. Within the present study the energy consumption of casting processes is analyzed and areas were great savings can be achieved are discussed. Lean thinking is used to identify waste and to analyse the energy saving potential for casting industry

The CRIMSON (Constrained Rapid Induction Melting Single Shot Up-Casting) method uses a rapid induction furnace to melt just enough metal for a single mould rather than bulk melting used in traditional casting process. The molten metal is then transferred to a computer – controlled platform to complete the counter-gravity up filling. The highly controlled metal flow is pushed into the mould to finish the pouring and solidification. In the present paper the energy saving capability of CRIMSON approach is compared with conventional sand casting process. The paper focuses on the energy and resource efficiency optimization of casting stages through simulation and life cycle assessment analysis simulation for proposing alternative means for the better performance of such processes. It is proven that the CRIMSON process can produce high quality castings with higher energy efficiency and lower environmental impact

Mesoporous silica molecular sieves MCM-41 were synthesized under hydrothermal conditions. For this purpose, a solution with a molar coefficient of water, cetyltri-methyl ammonium bromide surfactants as template and sodium silicate as the source of SiO2 are used. Phase formation, morphology and gas absorption properties were investigated by XRD and BET analysis, respectively. The results showed that silica mesoporous material has been successfully synthesized. A favorable special surface and porosity volume together with regular arrangement of nano metric-hexagonal porosities were obtained from this synthesis. Thickness of the wall and average diameter of the pores are 0.8nm and 4nm, respectively