Foundry & Forging worked example

Furnace Energy Cost with furnace connected or metered load of 330 kW: a worked example in foundry & forging

This worked example runs the furnace energy cost numbers for a tougher week than the baseline: furnace connected or metered load of 330 kW instead of the typical 650 kW. Estimate furnace energy cost for melting, holding, heat treatment, or preheat operations.

The inputs for this scenario

  • Furnace connected or metered load: 330 kW (the input this scenario stresses; the baseline uses 650)
  • Furnace runtime: 6 hr (held at the documented default)
  • Blended energy rate: 0.11 $ / kWh (held at the documented default)
  • Castings or forgings processed: 180 units (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Total furnace energy cost = furnace connected or metered load × furnace runtime × blended energy rate.
  • Total furnace energy cost works out to 218 $ at these inputs, and this is the headline figure for the scenario.
  • Furnace Energy Cost energy used works out to 1,980 kWh at these inputs.
  • Furnace Energy Cost cost per processed unit works out to 1.21 $ / piece at these inputs.
  • Hourly furnace energy cost works out to 36.3 $ / hr at these inputs.

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 49.23% below the baseline at 218 $.
  • Use it when quoting energy-intensive parts, benchmarking melt efficiency across heats, or building the business case for a power-supply or lining upgrade. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Total furnace energy cost: 218 $ (headline result)
  • Furnace Energy Cost energy used: 1,980 kWh
  • Furnace Energy Cost cost per processed unit: 1.21 $ / piece
  • Hourly furnace energy cost: 36.3 $ / hr

Run it with your numbers

  • To rerun this with your own numbers, open the live Furnace Energy Cost calculator, set furnace connected or metered load to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.