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

In: Advances and New Trends in Environmental Informatics

Author

Listed:
  • Ahmed ElFeky

    (German University in Cairo)

  • Hazem Elshiekh

    (Sequoia for Industrial Investments)

  • Amna Ramzy

    (German University in Cairo)

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.

Suggested Citation

  • Ahmed ElFeky & Hazem Elshiekh & Amna Ramzy, 2025. "Optimizing Foundry Operations: A Case Study on Improving Material and Energy Flow Efficiency in Line with the SDGs," Progress in IS, in: Volker Wohlgemuth & Hamdy Kandil & Amna Ramzy (ed.), Advances and New Trends in Environmental Informatics, pages 183-200, Springer.
    • Handle: RePEc:spr:prochp:978-3-031-85284-8_11
    DOI: 10.1007/978-3-031-85284-8_11
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