Wire Drawing & Rod Processing worked example

Annealing Energy with annealing furnace connected load of 6 kW: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop annealing furnace connected load to 6 kW, then walk the calculation through step by step. Annealing energy cost is the electricity spent softening drawn wire in a furnace, expressed both as a total and as a cost per annealed unit.

The inputs for this scenario

  • Annealing furnace connected load: 6 kW (the input this scenario stresses; the baseline uses 12)
  • Furnace runtime: 8 hr (held at the documented default)
  • Electricity tariff: 0.12 $ / kWh (held at the documented default)
  • Wire units annealed: 1,000 units (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Energy cost = connected load × runtime × energy rate.
  • Energy cost works out to 5.76 $ / unit at these inputs, and this is the headline figure for the scenario.
  • Energy used works out to 48 kWh at these inputs.
  • Cost per piece works out to 0.01 $ / piece at these inputs.
  • Hourly cost works out to 0.72 $ / hr at these inputs.

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 50% below the baseline at 5.76 $ / unit.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to annealing furnace connected load, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. 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: 5.76 $ / unit (headline result)
  • Energy used: 48 kWh
  • Cost per piece: 0.01 $ / piece
  • Hourly cost: 0.72 $ / hr

Run it with your numbers

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

Last reviewed 2026-05-12.