M
elting metal requires a lot of energy, and the metalcasting industry has
always been a major consumer of gas and electricity. As metalcasters begin emerging from the economic stress of the past few years, effective energy management can help companies reduce operating costs and improve profitability. In the coming years, the metalcast- ing industry will face many challenges,
including unpredictable energy market forces and the eventual effect of cli- mate control regulations, which could drive energy costs higher. According to the World Energy Council, energy currently comprises about 10% of the cost of manufactured goods, and that could escalate to as much as 25% in the next 10-15 years. It is estimated based on data available from the U.S. Environmental Protection Agency that metalcasters spent nearly $1.5 billion
on electricity and fuels in 2008, when production was at higher levels than in the past several years. A 5% reduc- tion across the industry would have amounted to $75 million in savings. Effective energy management is a
cost reduction strategy that can have an immediate impact on profitabil- ity and is a major component of an effective risk management strategy to protect against future energy rate increases and regulatory effects. With a strong commitment and a well- planned strategy, every metalcasting facility can become energy efficient. Te reduced energy costs derived from a focused program will free up money that can enhance profitability or be used to invest in other areas of the business. Reducing energy also can become a good marketing and public relations tool, demonstrating that your business is environmentally responsible and progressive.
Energy Management How does a metalcasting facil-
ity develop a comprehensive energy management program? It begins with understanding what equipment and processes are contributing to energy consumption and developing a means to measure energy use. Although melt- ing is the single biggest point of con- sumption (industry estimates indicate it is about 55% of the typical metal- caster’s energy bill), many points of use present opportunities to significantly reduce cost in several areas (Fig. 1). Metalcasting facilities that embark
on energy management will discover some relatively simple “low-hanging fruit” projects that can be implemented quickly for immediate improvement. However, effective energy management is more than a single project or two. It requires a holistic and comprehensive management strategy that includes a strong long-term commitment, a focused and structured program, and a change in company culture. Two keys to success have emerged
Fig. 1. Shown at bottom are the major points of energy consumption in the metalcasting facility, broken down by casting process. At top, the energy breakdown in a diecasting plant is shown.
20 | MODERN CASTING April 2011
from a recent U.S. Department of Energy program that included more than 50 U.S. metalcasting facility energy assessments:
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