Heat Treatment, Furnaces & Thermal Processing calculator
Energy Cost per Pound Calculator
Calculate electricity cost per pound of accepted heat-treated output. Use matching meter readings, the electricity tariff, separate demand allocation and net accepted weight.
What this calculator does
- Divide measured furnace electricity expense by the actual accepted output mass in pounds.
Formula used
- Metered electricity charge = load energy × energy-only tariff
- Load electricity expense = metered charge + separate demand allocation
- Energy cost per pound = load electricity expense ÷ accepted output pounds
- Energy per pound = load energy ÷ accepted output pounds
Inputs explained
- Metered Load Energy: Submeter consumption for the same load as the accepted weight.
- Energy-Only Electricity Rate: Consumption tariff excluding separately entered demand charges.
- Separate Demand Allocation: Documented load share of demand outside the consumption tariff.
- Accepted Output Mass: Scale-ticket net accepted product mass excluding fixtures.
How to use the result
- Best suited to Accepted-Weight energy Benchmark, furnace load cost comparison.
- Fuel and steam charges require separate matching energy inputs. This observed unit cost does not establish thermal efficiency.
Current U.S. benchmarks
- As of Jul 2026, industrial electricity averages 9.8 cents per kWh across the U.S. (EIA), up 4.7% from a year earlier. State averages range widely, so plants should confirm against their own tariff.
Common questions
- Why is fixture weight excluded? Fixtures consume energy but are not accepted product. Their heating expense remains in the numerator without increasing usable product weight.
- Can I divide by the original loaded weight? Only if all that net product weight was accepted. Use actual accepted weight when rejects or scale loss reduce output.
- How do demand charges enter the estimate? Enter the documented load allocation separately unless the electricity rate already includes it. Count the charge once.
- Does a lower result prove a more efficient furnace? No, tariffs, loading, part geometry and accepted yield also affect the result. Compare consistent jobs and inspect the accompanying kWh per pound.
Related guides
Last reviewed 2026-10-06.