Applications: Metals
Foundries operate some of the most energy-intensive processes used in any industry. Melting furnaces, grinders and annealing operations are examples of controllable loads where even small percentage reductions in peak demand can send large savings directly to the bottom line. Typical loads that the Energy Director optimizes include large-scale foundry and casting operations, sheet rolling, stamping and extrusion, electro-plating and anodizing, heat-treating, air handling & scrubbing, and ferrous and non-ferrous smelting and refining. Working with foundry loads, the Energy Director pays for itself with immediate demand cost savings of 10 – 40 percent and payback on investment in less than 18 months, sometimes less than half a year.
Case Study Overview:
Foote Foundry, LLC
Description: Specializes in gray and ductile iron castings. One of the country’s oldest continually operating green sand foundries, using 1000 kW and 1600 kW Ajax induction furnaces. Read more...
Installation Date: July 2005
Application: Controlling and reducing demand using only two furnaces.
Energy Savings: Average peak demand reduction of 513 kW; a 26 percent decrease in demand.
Project Payback: 16 months
Case Study Overview:
Gregg Industries - El Monte, CA
Description: A large gray and ductile iron foundry that specializes in manufacturing high ferrous iron castings for the industrial, automotive, and truck industries. Principal operations include melting iron in five ABB induction furnaces ranging from 1200 kW to 4500 kW each. Read more...
Installation Date: April 2004
Application: Using precise furnace control to reduce overall facility demand.
Energy Savings: Average peak demand reduction of 2300 kW; a 24 percent decrease in demand.
Project Payback: 18 months
Case Study Overview:
Pacific Alloy Castings - Southgate, CA: A modern, efficient producer of a wide range of high iron alloy castings with melting furnaces of 600kW and 1500kW. Read more...
Installation Date: September 2004
Application: Using precise furnace control to reduce overall facility demand.
Energy Savings: Average peak demand reduction of 600 kW; a 25 percent decrease in demand (which corresponds to a $3000 – $4000 per month in savings).
Project Payback: 18 months
Case Study Overview: Rochester Metals – Rochester, IN : Producer of quality gray iron castings from .75 pounds to 50 pounds. Read more...
Installation Date: February 2006
Application: Using precise furnace control to reduce overall facility demand; three 1500KW Ajax and two 7000KW Brown Boveri induction furnaces.
Energy Savings: Average peak demand reduction of 5,000 kW; a 24 percent decrease in demand (which corresponds to a $60,000 per month in savings).
Project Payback: 3 months
Foote Foundry