Growing interest in sustainability is driving manufacturers to improve the environmental performance of their products and processes. The production of steel and steel products consumes materials and energy resources, and creates wastes and emissions. Industry leaders and policy makers have identified iron/steel and metal casting as areas of concern from an environmental perspective. By evaluating steel product manufacturing processes commonly employed in the heavy equipment industry, environmental impacts can be mitigated during product and process design. A process modeling approach that is focused on improving the environmental performance of steel product manufacturing is developed and demonstrated. The process models focus on part production employing electric arc furnace (EAF) steelmaking and sand casting with chemical binders, and relate process energy and material inputs and outputs to product and process design characteristics. The models are based on scientific principles, as well as empirical data reported in the literature. Models of the two processes are applied to assess the production of a representative ground engaging tool (GET) component. It is found that EAF electricity use can be reduced by more than 30% and process-related CO2 emissions by nearly 20% over initial settings. Replacing the polyurethane nobake sand mold binder with a low nitrogen furan binder is predicted to reduce casting emissions by more than 50%, and sulfur dioxide emissions by over 90%. Thus, the models are capable of estimating changes in environmental performance due to modifications in material type, part geometry, and process parameters. This process modeling approach demonstrates improvements in environmental performance for the production of a GET component, and can be extended to assess and compare other steel alloys and components.
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e-mail: Karl.Haapala@oregonstate.edu
e-mail: Catalina_Adrian_V@cat.com
e-mail: Johnson_Michael_L@cat.com
e-mail: jwsuther@purdue.edu
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October 2012
Research Papers
Development and Application of Models for Steelmaking and Casting Environmental Performance
Karl R. Haapala,
e-mail: Karl.Haapala@oregonstate.edu
Karl R. Haapala
School of Mechanical, Industrial, and Manufacturing Engineering, Oregon State University
, 204 Rogers Hall, Corvallis, OR
97331
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Adrian V. Catalina,
e-mail: Catalina_Adrian_V@cat.com
Adrian V. Catalina
Product Development & Global Technology
, Caterpillar Inc., P.O. Box 1875, Peoria, IL
61656
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Michael L. Johnson,
e-mail: Johnson_Michael_L@cat.com
Michael L. Johnson
Product Development & Global Technology
, Caterpillar Inc., P.O. Box 1875, Peoria, IL
61656
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John W. Sutherland
e-mail: jwsuther@purdue.edu
John W. Sutherland
Division of Environmental and Ecological Engineering, Purdue University
, 322 Potter Engineering Center, West Lafayette, IN
47907
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Karl R. Haapala
School of Mechanical, Industrial, and Manufacturing Engineering, Oregon State University
, 204 Rogers Hall, Corvallis, OR
97331e-mail: Karl.Haapala@oregonstate.edu
Adrian V. Catalina
Product Development & Global Technology
, Caterpillar Inc., P.O. Box 1875, Peoria, IL
61656e-mail: Catalina_Adrian_V@cat.com
Michael L. Johnson
Product Development & Global Technology
, Caterpillar Inc., P.O. Box 1875, Peoria, IL
61656e-mail: Johnson_Michael_L@cat.com
John W. Sutherland
Division of Environmental and Ecological Engineering, Purdue University
, 322 Potter Engineering Center, West Lafayette, IN
47907e-mail: jwsuther@purdue.edu
J. Manuf. Sci. Eng. Oct 2012, 134(5): 051013 (13 pages)
Published Online: September 28, 2012
Article history
Received:
May 9, 2011
Revised:
August 4, 2012
Published:
September 25, 2012
Online:
September 28, 2012
Citation
Haapala, K. R., Catalina, A. V., Johnson, M. L., and Sutherland, J. W. (September 28, 2012). "Development and Application of Models for Steelmaking and Casting Environmental Performance." ASME. J. Manuf. Sci. Eng. October 2012; 134(5): 051013. https://doi.org/10.1115/1.4007463
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