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

Energy Assessments
Overall the assessment team was satisfied with the facility’s energy assessment practices. Steel
Foundry-1 has undergone a number of energy audits and assessments that have enabled the plant
to identify areas where it can improve its energy efficiency. The facility has completed the costeffective
process of purchasing new energy-efficient items and replacing older, less efficient
equipment when the older equipment fails. For example, the facility replaced overhead lights
with a higher efficiency variety as the existing bulbs failed, since it did not make economic sense
to replace its functioning bulbs with higher efficiency bulbs.
The assessment team recommended that the facility analyze whether all of its overhead lighting
is needed at all times and suggested that it consider minimizing bay lighting in favor of workplace
lighting. The cost of one 400-watt light bulb burning around the clock at $.05/kWh is $175
per year. According to plant personnel, this facility has 1,000 overhead lights burning
continuously. This means the foundry’s total cost for overhead lights is $175,200 per year. By
undertaking a program to use lighting only when needed, the foundry has the potential to achieve
significant savings in its energy bills.
3. Conclusion
Steel Foundry-1 has successfully implemented the positive results from a number of DOEsponsored
projects and reported on those results in industry literature. Steel foundry 1 has
implemented a number of technologies and practices that have reduced their energy efficiency
and improved their bottom line. There are still areas that Steel Foundry 1 could improve upon,
specifically in the compressed air and energy management area. These areas require little capital
investment to address.
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