Heat Treatment, Furnaces & Thermal Processing worked example

Energy Cost per Pound at 110% billable energy capture: a worked example

Push billable energy capture up to 110% and the picture changes. This example computes every intermediate figure at that operating point. Use it when heavy, dense, or low-volume furnace loads need energy cost normalized by pounds processed.

The inputs for this scenario

  • Energy consumed by the furnace load: 2,400 kWh (unchanged)
  • Electricity rate: 0.12 $ / kWh (unchanged)
  • Billable energy capture: 110 % (raised for this scenario; the documented default is 100)
  • Fixed demand or standby charge: 60 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Captured energy cost = heat treated load energy × utility rate × energy cost capture) to the inputs above produces each figure below.
  • At this operating point the engine returns 377 $ for total load energy cost, the number this scenario is built around.
  • At this operating point the engine returns 0.16 $ / kWh for energy cost per entered kwh.
  • At this operating point the engine returns 317 $ for captured energy cost.
  • At this operating point the engine returns 60 $ for fixed demand or standby adder.

How this compares with the baseline

  • Against the tool's baseline example, where billable energy capture sits at 100% and the headline result is 348 $, this scenario comes in 8.28% above the baseline at 377 $.
  • It computes the billable energy cost of one furnace load by applying a utility rate and capture factor to consumed kWh, then adds any fixed demand or standby charge. The value of this scenario is the size of the gap it exposes: that gap, priced out over a year, is the budget you can justify spending to close it.

Results at a glance

  • Total load energy cost: 377 $ (headline result)
  • Energy cost per entered kWh: 0.16 $ / kWh
  • Captured energy cost: 317 $
  • Fixed demand or standby adder: 60 $

Run it with your numbers

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

Last reviewed 2026-05-12.