Foundry & Forging worked example

Furnace Energy Cost with furnace connected or metered load of 1,600 kW: a worked example in foundry & forging

What does the result look like when furnace connected or metered load reaches 1,600 kW? The full calculation is worked below with real intermediate numbers. Use it when electricity, gas, induction power, or holding time is material to casting or forging cost.

The inputs for this scenario

  • Furnace connected or metered load: 1,600 kW (raised for this scenario; the documented default is 650)
  • Furnace runtime: 6 hr (unchanged)
  • Blended energy rate: 0.11 $ / kWh (unchanged)
  • Castings or forgings processed: 180 units (unchanged)

Working through the calculation

  • Applying the documented formula (Total furnace energy cost = furnace connected or metered load × furnace runtime × blended energy rate) to the inputs above produces each figure below.
  • At this operating point the engine returns 1,056 $ for total furnace energy cost, the number this scenario is built around.
  • At this operating point the engine returns 9,600 kWh for furnace energy cost energy used.
  • At this operating point the engine returns 5.87 $ / piece for furnace energy cost cost per processed unit.
  • At this operating point the engine returns 176 $ / hr for hourly furnace energy cost.

How this compares with the baseline

  • Against the tool's baseline example, where furnace connected or metered load sits at 650 kW and the headline result is 429 $, this scenario comes in 146% above the baseline at 1,056 $.
  • A figure at this level is achievable when furnace connected or metered load is genuinely sustained, not just peaked for a shift. Using connected load assumes the furnace draws near its rated kW for the full runtime; if the unit spends time at reduced hold power, metered kWh will be lower than this estimate and you should enter metered load instead.

Results at a glance

  • Total furnace energy cost: 1,056 $ (headline result)
  • Furnace Energy Cost energy used: 9,600 kWh
  • Furnace Energy Cost cost per processed unit: 5.87 $ / piece
  • Hourly furnace energy cost: 176 $ / hr

Run it with your numbers

  • Every input above is editable in the live Furnace Energy Cost calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.