Reduction of Energy Consumption and GHGs Emission in Conventional Sand Casting Process by Application of a New CRIMSON Process

Xiaojun DAI, Mark Jolly, Binxu ZENG


In conventional foundry, engineers generally consider the quality of casting part as the most essential issue and regard the energy consumption and Green House Gas (GHGs) emission as the auxiliary ones. This usually causes large amount of energy consumption as a result of the inefficient casting processes used and increases the production costs and environmental pollution. This paper presents the new CRIMSON process where its facility and melting process were compared with conventional melt furnaces and aluminium alloy melting process. An actual case was investigated to reveal quantitatively how the conventional foundry wastes energy and increases GHGs emission, and what the improvement of energy efficiency and the GHGs emission reduction can be achieved using the new CRIMSON process. The results of this investigation will help the foundry engineer recognize the importance of energy saving and environmental protection and show how to utilise this new process to reduce production costs and carbon footprint without decreasing the quality of the cast part.

Key words: Energy consumption; GHGs emission; Furnace; Aluminium; Sanding casting; Melting; CRIMSON


Energy consumption; GHGs emission; Furnace; Aluminium; Sanding casting; Melting; CRIMSON

Full Text:



[1] BSC, Incorporated. (2005). Advanced Melting Technologies: Energy Saving Concepts and Opportunities for the Metal Casting Industry. Report of U.S. Department of Energy.

[2] ENERGY CONSUMPTION GUIDE 38. (1997, 10). Non-ferrous foundries (Second edition). Department of the Environment, Transport and the Regions.

[3] Klaasen, B., Jones, P.T., Durinck, D., Dewulf, J., Wollants, P., & Blanpain, B. (2010). Exergy-Based Efficiency Analysis of Pyrometallurgical Processes. Metallurgical and Materials Transactions B, 41(6), 1205-1219.

[4] Eppich, R., & Naranjo, R.D. (2007). Implementation of Metal Casting Best Practices. Report of U.S. Department of Energy.

[5] Margolis, N. (1997). Energy and Environmental Profile of the U.S. Aluminium Industry. Report Prepared by GNERGETICS, Inc. Columbia, Maryland, U.S. Department of Energy, Office of Industrial Technologies.

[6] Jolly, M. (2010, 2). Energy Saving in the Foundry Industry by Using the “CRIMSON” Single Shot UP-Casting Process. 2010 TMS Annual Meeting & Exhibition, Seattle, WA.

[7] Geelin, J. C; Lovis, M, & Jolly, M.R. (2006, 3). Simulation of Tensile Test Bars: Does the Filling Method Matter? In Q. Wang, M.J.M Krane, & P.D Le (Ed.), Symposium on Simulation of Aluminum Shape Casting Processing, TMS2006, Warrendale, PA.

[8] Li, T.X, Hassan, M, Kuwana, K, Saito, K, & King, P. (2006). Performance of Secondary Aluminium Melting: Thermodynamic Analysis and Plant-Site Experiments. Energy, 31(12), 1769-1779.

[9] Rosen, M. A. (2009). Exergy-based Analysis and Efficiency Evaluation for an Aluminium Melting Furnace in a Die-casting Plant. Proceedings of the 4th IASME/WSEAS International Conference on ENERGY & ENVIORMENT (EE’09).

[10] Energy density. Retrieved from Wikipedia,

[11] Dai, X, & Jolly, M. (2012 January). Potential Energy Savings by Application of the Novel CRIMSON Aluminium Casting Process. Applied Energy, 89(1), 111-116.

[12] Spadaro, J. V., Langlois, L., & Hamilton, B. (2000). Greenhouse Gas Emission of Electricity Generation Chains - Assessing the Difference. IAEA BULLETIN.

[13] Power station. Retrieved from Wikipedia,




  • There are currently no refbacks.

Copyright (c)

Share us to:   


If you have already registered in Journal A and plan to submit article(s) to Journal B, please click the CATEGORIES, or JOURNALS A-Z on the right side of the "HOME".

We only use three mailboxes as follows to deal with issues about paper acceptance, payment and submission of electronic versions of our journals to databases:;;

 Articles published in Energy Science and Technology are licensed under Creative Commons Attribution 4.0 (CC-BY).


Address: 1055 Rue Lucien-L'Allier, Unit #772, Montreal, QC H3G 3C4, Canada.
Telephone: 1-514-558 6138 
Website: Http:// Http://;

Copyright © 2010 Canadian Research & Development Centre of Sciences and Cultures