Optimizing Foundry Operations: A Case Study on Improving Material and Energy Flow Efficiency in Line with the SDGs

Ahmed ElFeky (), Hazem Elshiekh and Amna Ramzy
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Ahmed ElFeky: German University in Cairo
Hazem Elshiekh: Sequoia for Industrial Investments
Amna Ramzy: German University in Cairo

A chapter in Advances and New Trends in Environmental Informatics, 2025, pp 183-200 from Springer

Abstract: Abstract This study focuses on optimizing material and energy flows within a foundry to enhance sustainability and align with Sustainable Development Goals (SDGs) 9 (Industry, Innovation, and Infrastructure) and 12 (Responsible Consumption and Production). Using UMBERTO® Efficiency + software, key inefficiencies were identified, particularly in the induction furnaces, which consumed 85% of the facility’s total energy. By implementing targeted optimization strategies, the foundry achieved significant improvements, including expected annual energy savings of 429,312 kWh and a reduction of 236 metric tons of CO2 emissions. Additionally, reclassifying iron shavings by alloy type led to an increased revenue of 74,690 EGP, totaling 329,890 EGP. These results demonstrate that systematic resource management can greatly enhance both economic and environmental outcomes. This approach not only improves operational efficiency but also contributes to global efforts in achieving more sustainable industrial practices, in line with the SDGs.

Keywords: Material and Energy Flow Optimization; Sustainable Development Goals (SDGs); Industrial Efficiency; Greenhouse Gas Emissions Reduction; Foundry Operations; Resource Management; Modelling and simulation (search for similar items in EconPapers)
Date: 2025
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DOI: 10.1007/978-3-031-85284-8_11

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