Wisconsin Foundry Industry Overview

1
Wisconsin Foundry Industry Overview

• 125 foundries
• 80 - 100 employees or less
• 21,000 employees
• Payroll 870 million
• 3.5 billion in sales
• Wisconsin 3d Ranked Foundry State
• Nationally 200 250 trillion Btu per year

2
WCMA Energy Initiatives

• Focus on education and facilitation
• Incorporated energy issues into the standing
  Environmental Committee
• Best Practices Handbook May 2006 Workshop
• Targeted Site Assessments future Regional
  Workshops
• No goal set to date

3
Foundry Industry Barriers to Energy Reduction

• International competition priority is survival
  and market-share. Capital priorities.
• Demographics ? internal resources (many hats for
  one individual)
• Environmental requirements air pollution
  control

4
Energy Use Profile Cupola Shop
APC/AMU
5
Foundry Support

• Small Foundries will require more individual
  attention and financial assistance
• Large Foundries continued financial incentives
  and tax credits
• All require education/awareness and
  research/development

6
Assistance Model
Research AFS Universities
DOE Industrial Technologies Program
Focus on Energy
Local Foundry
WCMA
7
Assistance Considerations

• Existing model is effective
• Do not forget about the basics
• Do not assume that a 2 year pay back is a slam
  dunk

8
Historical Practices

• Scrap recycling ? life cycle perspective
• Sand recycling ? life cycle perspective
• Preheat of cupola blast air (1980)
• Inductor and furnace efficiency
• Purchasing practices

9
Recent Energy Reduction Activities

• Compressor system modifications and control
• Cupola heat recovery for space heat ? 50,000
  dekatherm annual savings
• Lighting Projects ? 325K invested to date
• Premium efficiency motor project

10
Future Reduction Activities

• HVAC smart building controls
• Plant 1 Cupola Heat Recovery
• Compressor System Retrofits
• Lighting Retrofits
• Waste Heat to Electricity ? 8 MW (long
  term 6 8 year payback)