Energy Cost Reduction

1.Melt ferrous metal using at least two induction furnaces.

The bigger and the more the furnaces the better! As the number of furnaces increases so does the potential for the plant to create coincidental demand peaks (every load running hot and heavy during the 15-minute demand interval). The bigger the furnaces, the greater the coincidental peak. Our energy system manages those coincidental peaks out of your demand profile, reducing the demand charge.
We have systems where the only electrical load on a meter (bill) is one furnace. Our system still was able to reduce the demand by 15%. But, the furnace must be greater than 1000kW.
The furnaces can be an arc furnace. But, generally these furnaces are difficult to integrate with so the project cost increases.
The furnaces can be electric resistive. Generally, these are smaller furnaces (50 to 300kW range) so we would want several of these.
The furnaces can be used for holding molten metal like in Al-die casting plants where you may have several electric holding furnaces. The key here is that we need at least a few to make this work.

2. Plant demand greater than 2000kW

Minimum: We can go as low as 500kW, but you have to have a high demand charge and the majority of the 500kW must be used by furnaces.

3. Demand charge greater than $6/kW

Minimum: Can go as low as $2/kW, but you must meet (or be close) to both 1 and 2 above.
Given these minimums, here is a good example of barely meeting those minimum qualifications: XYZ Foundry's average monthly demand before our system was 1900kW. They had 1000kW and 1600kW induction furnaces. Their demand charge was only $2.81/kW. Additionally, the two furnaces were the only electric loads on that bill.

For more information please fill out the request form below. You will be contacted by a buyCASTINGS representative.