The power of all kinds of equipment in the production department of FE1, FE2 and FE3, such as flow coating machine, sand mixer, machining center, molding machine, etc., takes the rated power of the equipment. In the calculation, the carbon emission coefficients of different energy and materials are obtained by reference.
Figure 1 shows the comparison of all kinds of carbon emissions of the three process schemes, from which we can clearly see the differences in carbon emissions caused by different process designs. Among them, scrap is the most important carbon emission source in the production process. It can be seen that the carbon emission of scrap steel in FE1 is the most among the three process schemes, because FE1 does not use sand core to make holes and needs to smelt a lot of scrap steel. In addition, smelting energy is a secondary source of carbon emissions. Because both FE2 and FE3 use sand cores, the amount of molten iron smelted is reduced, thus reducing carbon emissions from smelting energy. Reducing molten metal is an important optimization means to reduce carbon emissions. When designing and optimizing the new process plan, reducing the use of materials in this smelting stage as much as possible can effectively reduce carbon emissions. It is suggested that we should focus on the structural upgrading of iron and steel plants and other enterprises to reduce the carbon emissions of materials, so as to reduce the overall carbon emissions of the foundry industry and other manufacturing industries.
It can be seen from figure 2 that the material carbon emission is the highest in the sand casting process. The carbon emission of FE2 is 1.229% lower than that of FE3, and the carbon emission of FE1 FE3 is 1.470% lower than that of FE1. The impact on the environment is minimal. Among the process parameters related to the geometric structure characteristics of castings, the hole processing margin and the structural parameters of sand core have an important influence on scrap and smelting. FE3 is the process plan that optimizes these process parameters. It can be seen from the diagram that the overall carbon emission of FE3 is the least, and the optimized scheme has better emission reduction capacity.