Wire Drawing & Rod Processing worked example

Annealing Energy with annealing furnace connected load of 30 kW: a worked example

What does the result look like when annealing furnace connected load reaches 30 kW? The full calculation is worked below with real intermediate numbers. Use it when annealing energy in wire drawing and rod processing is being quoted and energy is a real chunk of the wire drawing and rod processing cost stack.

The inputs for this scenario

  • Annealing furnace connected load: 30 kW (raised for this scenario; the documented default is 12)
  • Furnace runtime: 8 hr (unchanged)
  • Electricity tariff: 0.12 $ / kWh (unchanged)
  • Wire units annealed: 1,000 units (unchanged)

Working through the calculation

  • Applying the documented formula (Energy cost = connected load × runtime × energy rate) to the inputs above produces each figure below.
  • At this operating point the engine returns 28.8 $ / unit for energy cost, the number this scenario is built around.
  • At this operating point the engine returns 240 kWh for energy used.
  • At this operating point the engine returns 0.03 $ / piece for cost per piece.
  • At this operating point the engine returns 3.6 $ / hr for hourly cost.

How this compares with the baseline

  • Against the tool's baseline example, where annealing furnace connected load sits at 12 kW and the headline result is 11.52 $ / unit, this scenario comes in 150% above the baseline at 28.8 $ / unit.
  • A figure at this level is achievable when annealing furnace connected load is genuinely sustained, not just peaked for a shift. It uses connected load as if the furnace draws full power the whole time; furnaces cycle on and off around a setpoint, so actual consumption is usually lower than nameplate load implies.

Results at a glance

  • Energy cost: 28.8 $ / unit (headline result)
  • Energy used: 240 kWh
  • Cost per piece: 0.03 $ / piece
  • Hourly cost: 3.6 $ / hr

Run it with your numbers

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

Last reviewed 2026-05-12.