Heat Treatment, Furnaces & Thermal Processing worked example

Energy Cost per Pound at 72% billable energy capture: a worked example

Suppose billable energy capture falls to 72%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Estimate energy cost per pound for heat treated load weight using energy consumption, utility rate, capture percent, and fixed energy adders.

The inputs for this scenario

  • Energy consumed by the furnace load: 2,400 kWh (held at the documented default)
  • Electricity rate: 0.12 $ / kWh (held at the documented default)
  • Billable energy capture: 72 % (the input this scenario stresses; the baseline uses 100)
  • Fixed demand or standby charge: 60 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Captured energy cost = heat treated load energy × utility rate × energy cost capture.
  • Total load energy cost works out to 267 $ at these inputs, and this is the headline figure for the scenario.
  • Energy cost per entered kWh works out to 0.11 $ / kWh at these inputs.
  • Captured energy cost works out to 207 $ at these inputs.
  • Fixed demand or standby adder works out to 60 $ at these inputs.

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 23.17% below the baseline at 267 $.
  • 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. When the numbers land here, the stressed input is the lever to work; the walkthrough above shows exactly how much each output recovers as it climbs back toward the baseline.

Results at a glance

  • Total load energy cost: 267 $ (headline result)
  • Energy cost per entered kWh: 0.11 $ / kWh
  • Captured energy cost: 207 $
  • Fixed demand or standby adder: 60 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Energy Cost per Pound calculator, set billable energy capture to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.