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Wisconsin Foundry Industry Overview

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. WCMA Energy Initiatives. Focus on education and facilitation

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Wisconsin Foundry Industry Overview

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  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 DOE – Industrial Technologies Program Research *AFS * Universities 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)

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