1. Energy Requirements for Typical Green Sand Foundry sand-binder mixing core forming core curing mold & core assembly mold pouring, cooling shakeout riser cutoff & gate removal cleaning, finishing, coating QA / shipping mold making sand renewal metal melting slag, dross removal scrap preparation 1.2-3.5 MJ/kg saleable casting 1.2 MJ/kg 0.7 MJ/kg Melting (MJ/kg) Cupola 6.7 Coke 1.3 Electricity 1.9 Natural Gas 0.1 Oxygen Electric melting 5.0-5.6 Induction 5.0-6.0 Electric Arc 6.0-9.2 Reverb Fuel fired melting 2.1-7.9 Crucible 2.9-5.8 Reverb

2. Energy Requirements for Typical Green Sand Foundry By Mass Fuel sand-binder mixing core forming core curing mold & core assembly mold pouring, cooling shakeout riser cutoff & gate removal cleaning, finishing, coating QA / shipping mold making sand renewal metal melting slag, dross removal scrap preparation 100-300g fossil fuel/kg saleable casting 100 g/kg 60 g/kg Melting (g/kg) Cupola 170 Coke 120 Electricity 50 Natural Gas 5 Oxygen Electric melting 450-500 Induction 450-550 Electric Arc 550-800 Reverb Fuel fired melting 50-200 Crucible 73-150 Reverb

3. Fuel Requirements Using Williams’ conversion –320 g fossil fuel/kWh electricity –40 MJ/kg of nonelectric fuel 1 kilogram casting using EAF requires 900 g fossil fuel 1 kg casting using coke cupola requires 550 g fossil fuel –Disparities caused by efficiency of electricity production, size(?)