Implementation of Metal Casting Best Practices - EERE - U.S. ...

Exhibit 9: Nationwide Locations of the IACs
Once an assessment is completed, the IAC team provides a detailed report of its analysis,
findings, and recommendations to the plant within 60 days. On average, the implementation of
actions recommended by the IAC results in an annual savings of $55,000 per plant. Exhibit 10
lists some of the recommendations made by the IACs to metal casters, their average
implementation costs, and their resultant annual savings. To learn more about these and the
Center locations, visit http://iac.rutgers.edu/database * .
Facility
Type
Gray and
Ductile Iron
Foundry
Steel
Investment
Foundry
Yearly
Energy
Costs
$1,694,719
$2,171,872
Exhibit 10: Recent IAC Recommendations to Metal Casters
Recommendation
Cost to
Implement
($)
Annual
Savings
($)
Payback
Period
(Yr)
Automatic Grinding Stations $250,000 $269,280 0.9
Replace No. 2 Fuel Oil Furnace with an Electric
Furnace
$40,000 $55,434 0.7
Improve and Maintain the Insulating Dome Lids
on Furnaces
$10,000 $52,852 0.2
Repair Leaks in Compressed Air Lines $2,484 $19,606 0.1
Install an Air/Air Heat Exchanger to Retain
Exhaust Air Heat
$150,000 $35,862 4.2
Reduce Charging Time by Use of Gated
Feeders
$50,000 $22,098 2.3
Replace Drive Belts on Motors with Energy
Efficient Cog Belts
$840 $864 1.0
Schedule Induction Melters to Reduce Peak
Demand
$20,000 $41,580 0.5
Convert Boiler Clave to Steam Heat $15,605 $13,555 1.2
Preheat Burnout Oven Combustion Air $9,830 $5,980 1.6
Retrofit Lighting Fixtures to High Efficiency
Bulbs
$12,543 $4,977 2.5
Turn Off Furnace Blowers During Cool Down $1,039 $3,918 0.3
Repair Compressed Air Leaks $600 $3,228 0.2
* The IAC database contains hundreds of assessments where hundreds of recommendations from previous
assessments are stored. Exhibit 10 displays a select few of those recommendations.
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