Energy Efficiency in Foundries and Melting

Copyright ©
2013,

North Carolina Advanced Energy Corporation. All rights reserved.

Copyright ©
2013 North
Carolina Advanced Energy Corporation. All rights reserved. No part of this

presentation

may be reproduced, distributed

or transm
itted in any form or by any means,

electronic or mechanical, including photocopying, recording, or

by use of any information storage and retrieval system, without

the written consent of

North Carolina Advanced Energy Corporation.

Energy Efficiency
in Foundries and
Melting

Copyright ©
2013,

North Carolina Advanced Energy Corporation. All rights reserved.

Introduction

Energy Efficiency in Foundries and Melting

Copyright ©
2013,

North Carolina Advanced Energy Corporation. All rights reserved.

Introduction


Sustainable Energy Efficiency


Foundry Industry Data


Foundry Energy Consumption


Energy Prospecting


Teamwork


Case Studies


Wrap
-
Up



Topic Outline:

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Sustainable Energy Efficiency


Sustainable:

The capacity to support, maintain, or
endure


Energy:

The ability of one physical system to do work on
another physical system causing a
transformation


Efficiency:

The ratio between a specific, useful
output

and
the required energy
input

Sustainable Energy Efficiency:



ENDURING

TRANSFORMATION

with an ever
increasing
OUTPUT

per unit of
INPUT


More TONS per BTU:

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Sustainable Energy Efficiency

0
1
2
3
4
5
6
7
Jan-13
Feb-13
Mar-13
Apr-13
May-13
Jun-13
Jul-13
Aug-13
Sep-13
Oct-13
Nov-13
Dec-13
Jan-14
Feb-14
Mar-14
Apr-14
BTU x 10
6

per TON of Melt

MONTH

Melt Energy Intensity


A Good SUSTAINED Trend

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Sustainable Energy Efficiency

Fuel Group

Energy Source

Pounds

of CO
2

Per
Million BTU

Coal

Bituminous

and
Anthracite Coal

Lignite Coal

205.3


215.07

Natural Gas

Natural Gas

Propane

117.1

139.2

Nuclear

Nuclear

0.0

Renewable ( non
-
Biomass)

Solar (PV)

Geothermal

Hydro

Wind

0.0

16.6

0.0

0.0

Biomass

Landfill gas

Sludge Waste

Wood

waste solids

115.1

199.5

195.0

Note
:

1 Million BTU = 0.293 MWh

1 MWh =3.412 Million BTU

Source:
http://cta.ornl.gov/bedb/biopow
er/Carbon_Dioxide_Uncontroll
ed_Emission_Factors.pdf


CO
2

Emissions by Electrical Power Generation Type

Depending on your utility
electrical generation mix,
you can determine your
electrical consumption
CO
2

footprint.

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2013,

North Carolina Advanced Energy Corporation. All rights reserved.

Foundry Industry Data


Ferrous Metal Foundry Info (NAICS Code 33151)


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Foundry Industry Data


Estimated Metal Casting Energy Use by Metal Type

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North Carolina Advanced Energy Corporation. All rights reserved.

Foundry Industry Data


Estimated Metal Casting Energy Use by Energy Type

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North Carolina Advanced Energy Corporation. All rights reserved.

Foundry Industry Data


Estimated Metal Casting Energy Use by Process Type


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Foundry Energy Consumption

Total Annual Primary
Energy Usage in Industrial
and Other Sectors in USA

A big slice of the pie!

Source: US Energy Information Administration (EIA), Annual Energy
Outlook(AEO
) Report, 2012;
www.eia.gov/forecasts/aeo


~12%


The really BIG Picture…..

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Foundry Energy Consumption


Perspective…..

>

383 Trillion BTUs =

>
E
quivalent to the reactors on 1,439 James
Madison Class ballistic missile nuclear subs

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Foundry Energy Consumption

Total Gas Intensity (kBtu/sqft, annual basis): 1,183.64

Average Gas Consumption per Establishment (kBtu): 206,894,400

Average Enclosed Floorspace per Establishment (sqft):
174,795


Source: EIA energy intensity data from CBECS and MECS, EPRI, and other third party
energy use datasets.


Natural Gas Energy Usage
-

Primary Metals


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Foundry Energy Consumption

Total Electric

Intensity (kWh/sqft, annual basis):
262.73

Average Electric Consumption per Establishment (kWh):
45,923,890

Average
Enclosed
Floorspace per Establishment (sqft):
174,795


Source: EIA energy intensity data from CBECS and MECS, EPRI, and other third party
energy use datasets.


Electrical Energy Usage
-

Primary Metals:


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Foundry Energy Consumption


Manufacturing Energy
–

FOUNDRIES (NAICS 3315)


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Foundry Energy Consumption


Energy Use per TON for Various Processes
-
STEEL


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Foundry Energy Consumption


Energy
Use
per
POUND
for
Various Processes
-

ALUMINUM

Isothermal

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Energy Prospecting

Combing through the foundry, often through basements,
side rooms, in utility buildings and in boiler rooms, often
on hands and knees looking for signs of wasted BTU’s
in the infrastructure. In the case of heat, all streams in a
plant should be checked at the appropriate production
points looking for an opportunity to improve energy
efficiency in the transformation processes.


Prospecting for Energy Savings in the Foundry

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Energy Prospecting


PRODUCT:

An article or substance that is
manufactured or refined for sale


PROCESS:

A series of actions or steps taken to
achieve an end; procedures involving chemical or
mechanical steps to aid in the manufacture of an item or
items, usually carried out on a very large scale


TRANSFORMATION:

A thorough or dramatic change
in form or appearance

ENDURING

TRANSFORMATION

with an
ever increasing
OUTPUT

per unit of
INPUT

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Energy Prospecting


For foundries, the
transformation

is focused on MELTING

>
The
e
nergy intensity is focused on
BTU per Ton

>
60% to 80%

of the energy is used for the melting & holding

>
Other potential areas to look for
energy savings
:


Demand Side Management


Waste Heat Recovery


Compressed Air


Motors & Variable
Frequency
Drives


Boilers / Furnaces / Combustion


The Plant Team

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Energy Prospecting


Demand Side Management

>
Typical electrical
invoices are composed of two major
portions:


Energy

charge for actual kilowatt
-
hours consumed during the
billing
period


Demand

charge for the level of the single highest kilowatt
demand power level for any given
interval period
over the entire
billing
cycle

>
This demand charge is based on a peak power level. By
establishing both procedural controls and possibly automated
controls, there is an opportunity to reduce this peak demand and
therefore reduce the demand portion of the electrical bill



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Energy Prospecting


Demand Side Management

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Energy Prospecting


Waste Heat Recovery

>
From Melting

>
From Holding

>
From Boilers

>
From Combustion

>
From Compression


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2013,

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Energy Prospecting


Some Possible Uses for Waste Heat

>
Building Heating

>
Steam Production

>
Preheating Combustion Air

>
Preheating Feed Water for Boilers

>
Absorption and Adsorption Chillers

>
Heat Pumps

>
Dehumidification of Cupola Blast Air

>
Downstream Drying or Curing Processes

>
On
-
Site Electrical Power Generation


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2013,

North Carolina Advanced Energy Corporation. All rights reserved.

Energy Prospecting


Compressed Air

>
Compressed air systems have
an efficiency
of
around
15%

>
A 150
hp air
compressor,
fully loaded for one year at $0.05
per
kWhr
will cost
$50,000

per year for the
electricity

>
Typically there is an attitude in the plant that compressed air
is free, which can lead to
improper uses

>
Compressed air systems
always

have
leaks


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Energy Prospecting


Compressed Air

>
Educate Employees on the real COST of compressed air

>
Conduct
Plant Surveys on END USES
–

Remove Improper Uses

>
Develop and Maintain a strong LEAK Repair Program

>
Right Size compressors and base load / trim with VFD’s

>
Reduce Overall System Pressure to minimum possible

>
Evaluate and Update systems controls

>
Evaluate Alternatives: Motors, Blowers, Mechanical Actuators, etc.

>
Evaluate Waste Heat Recovery

>
Bag Houses
–

Evaluate the System

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Energy Prospecting


Motors and Variable Frequency Drives (VFD’s)

>
Electric motors typically account for around
30% of
all the electricity
consumed in primary metals manufacturing
plants


Air Compressors, Chillers & HVAC, Fans for Cupola Operations,
Hydraulics, Material Handling, etc.

>
Effectively managing the motor population in a manufacturing plant
can
typically save up to 8% in motor energy costs

>
VFD’s on properly selected motors can result is dramatic savings


Horsepower is proportional to speed (rpm) CUBED

▫
HP ~ rpm
3

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2013,

North Carolina Advanced Energy Corporation. All rights reserved.

Energy Prospecting


Motors and Variable Frequency Drives (VFD’s)

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2013,

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Energy Prospecting


Motors and Variable Frequency Drives (VFD’s)

>
On
-
site training
on Motor Management Policy
concepts for:


Maintenance
Staff, Engineers, Purchasing, Operations

>
Set up a system for collecting
and processing motor nameplate data

>
Establish motor
repair or replace guidelines

>
Motor and
drive
testing and
evaluation

>
Right size motors: Below 40% Load


Efficiency DROPS significantly

>
Evaluate Use of Premium Efficient Motors


Use Life Cycle Costing




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2013,

North Carolina Advanced Energy Corporation. All rights reserved.

Energy Prospecting


Boilers / Furnaces / Combustion


Balance Air and Fuel

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North Carolina Advanced Energy Corporation. All rights reserved.

Energy Prospecting


Boilers / Furnaces / Combustion


>
Understand Losses

>
Each 40
⁰
F

decrease in stack temperature
results in a 1% increase in efficiency

>
Preheat Combustion Air


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2013,

North Carolina Advanced Energy Corporation. All rights reserved.

Energy Prospecting


Involve Everyone
o
n the Plant Team
in
Energy Efficiency
:

>
Product Design

>
Purchasing

>
Finance

>
Operators

>
Maintenance

>
Plant
Engineering

>
Energy Teams

>
Utility Account Managers

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2013,

North Carolina Advanced Energy Corporation. All rights reserved.

Energy Prospecting


Remember Renewable Energy Opportunities

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North Carolina Advanced Energy Corporation. All rights reserved.

Energy Prospecting


Other Benefits of Energy Efficiency Improvements

>
Increase
plant
productivity

>
Improve
product quality

>
Improve worker comfort

>
Increase available
floor space

>
Improve work flow

>
Reduce
emissions

>
Improve safety

>
Increase profits

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2013,

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Teamwork


Foundries are very ENERGY INTENSE

>
Your local utility or energy consultant can
HELP


Assistance with Capital Projects

▫
New Equipment Planning

▫
Capital Expansions

▫
Greenfield Projects


Infrastructure


Business Continuity


Incentive Programs


Other Energy Efficiency Programs

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Teamwork


Assistance with Capital
Projects

>
Consider Electrical Rate Structure Options


Best Rates Analysis


Demand Response Programs


Energy Efficiency Options

>
Economic Development Discounts for new load and job
creation expansions

>
Contact your local utility or account manager
EARLY

in
the planning process of your project

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Teamwork


Infrastructure

>
Take delivery at the primary voltage

>
The Utility can bid and turn key install:


Substations


Transformers


Switchgear


Main Feeder lines to Furnaces

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North Carolina Advanced Energy Corporation. All rights reserved.

Teamwork


Business Continuity

>
Backup Generation for:


Entire plant loads


Critical loads only

>
The Utility can design, build and install:


On
-
Site Generation


Uninterruptible Power Supplies

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Teamwork


Incentive Programs

>
Typical Areas for
Standard Incentives


Lighting


Demand Side Management Controllers


Variable Speed Drives and Motors


Chillers and HVAC Units

>
Custom Incentives


Plan Ahead. Approval is required
BEFORE

issue of the
purchase order for equipment and energy savings typically
need to be verified.

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Teamwork


Other Energy Efficiency Programs

>
ISO 50001
–

Energy Management System

>
Department of Energy, Superior Energy Performance (DOE SEP)

>
Government Incentives for Renewable Energy
= DSIRE™

>
Electrical Power Research Institute (EPRI)

>
Environmental Protection Agency (EPA) Energy Star

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2013,

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Teamwork

To Find the Best Available Energy
Efficient Solution

Vendors

Consultants

Utilities


Foundries working together with:


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2013,

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Case Study
-

Teamwork


Working together for the Best Solution

>
End User

>
Equipment Vendor

>
Utility


Planning


Infrastructure


Energy Efficient Equipment


Induction Melting


Total Turn Key Solution


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2013,

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Case Study
-

Teamwork


Early in the Project

Bring in the
UTILITY

for project planning:

>
New Melting Project

>
Economic Development Review

>
Utility Rate Options

>
Utility Process Heating Expertise

>
Electrical Infrastructure Planning and Proposal

>
Turn Key Installation Solution



Site Selection: GREENWOOD, SC

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Ingersoll Rand Mocksville NC

Case Study
-

Teamwork


Electrical Infrastructure

>
Delivery of Primary Voltage to site


U
sing unique
voltage gave us
the
opportunity to
provide custom transformation and high voltage lines
directly to
the
furnaces
–

Duke Energy

>
Installation of Substation, Switchgear, and
Main Feeder Lines in a Turn Key Solution

>
Crown Casting
-

A Satisfied Customer:


Duke Energy was able to provide a total solution
which lead us to select this location for our new
foundry
–

Crown Casting

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North Carolina Advanced Energy Corporation. All rights reserved.

Ingersoll Rand Mocksville NC

Case Study
-

Teamwork


Equipment Vendor
-
Best Technology

Induction Melting
-

Benefits

>
Re
duced Emissions
–

Lower CO
2

footprint

>
Energy Efficiency

–

Overall 55
-
75% efficient

>
Higher Yield
–

No oxidation losses

>
Faster Start
-
Up

–

Full “Power ON” instantaneously

>
Product Optimization

–

Precise temperature control and good
stirring effect for homogeneous batches

>
Flexibility and Automation

–

Cold Start, Alloy Changes, Automated
Controls

>
Space Saving

–

High melt rates per furnace footprint

>
Improved Working Environment

–

Quieter, no combustion, reduced
waste heat

ENDURING

TRANSFORMATION

with an
ever increasing
OUTPUT

per unit of
INPUT

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2013,

North Carolina Advanced Energy Corporation. All rights reserved.

Case Study
-
Teamwork

Equipment
Selection:



The new equipment at the Crown Casting facility is a 4000
kW VIP Dual
Trak Induction Melting System ,
with two 5
MT coreless furnaces
for IRON
melting. When one furnace is melting, the other furnace is holding.

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2013,

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Case Study
-
Demand Side Mgmt

“
Powerit Solutions provided our business with a system that controls our electrical
demand very
well and they were able to meet our tight delivery requirements at a
competitive cost
.”
Doug
Smith, Project Engineer, Rochester Metal Products

Prior to implementing the system, Rochester
Metals
´

typical
monthly peak
demand was 21,000 kW.
They tested
the system for a month at 18,000 kW,
and
when
they were able to maintain production,
they adjusted
the
set point
to
17,000 kW. Again,
there was no production
loss, so they readjusted
the set
point
to 16,000 kW, which is where it
remains today
with no production loss.

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2013,

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Case
Study
-
Demand Side Mgmt

“We are very
satisfied
. Powerit Solutions' system has
fulfilled all
our expectations as
well as the
estimated savings.”
Mark
Regus, Plant Manager,
Pacific
Alloy

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2013,

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Training Opportunity


1
st

Annual Electrotechnologies Seminar





Oct
. 21
-
22, 2013, The Conrad
Hotel, Indianapolis
, IN

>

There are two
tracks:


Track ONE:

Electrotechnologies for Drying, Curing, and
Finishing


Track TWO:

Electrotechnologies for Processing
Metals




Copyright ©
2013,

North Carolina Advanced Energy Corporation. All rights reserved.

Wrap Up

Review Our Topics:


Sustainable Energy Efficiency




Foundry Industry Data


Foundry Energy Consumption

ENDURING

TRANSFORMATION

with an ever increasing
OUTPUT

per
unit of
INPUT

Copyright ©
2013,

North Carolina Advanced Energy Corporation. All rights reserved.

Wrap Up

Review Our Topics (continued):


Energy
Prospecting
–

Plant Wide


Teamwork

▫
To identify the most efficient melting technology

▫
To provide guidance on infrastructure

▫
To assist with financial analysis and capital requests


Case
Studies

Copyright ©
2013,

North Carolina Advanced Energy Corporation. All rights reserved.

Contributors

Michael P. Looby

District Manager,
Southeast USA

Baskar Vairamohan, CEM

Senior Project Engineer

George Bowyer

VP Operations

W. Roger Paules, Jr., PE, CEM

Program Manager | Energy Utilization

Copyright ©
2013,

North Carolina Advanced Energy Corporation. All rights reserved.

Sources


INFORMATION SOURCES:

>
Advanced Energy:


www.advancedenergy.org

>
Advanced Energy Motor Info:


www.advancedenergy.org/md/knowledge_library/resources/Horsepower%20Bulletin.pdf

>
Advanced Manufacturing Office
–

Compressed Air Systems


www1.eere.energy.gov/manufacturing/tech_deployment/compressed_air.html

>
Advanced Manufacturing Office
–

Energy Resource Center


www1.eere.energy.gov/manufacturing/tech_deployment/ecenter.html

>
American Foundry Society


www.afsinc.org
/

>
Dibalog


www.dibalog.com/

>
Duke Energy


www.duke
-
energy.com/company.asp


Copyright ©
2013,

North Carolina Advanced Energy Corporation. All rights reserved.

Sources


INFORMATION SOURCES (continued):

>
Duke
Energy Smart $aver® Incentive
Program


www.duke
-
energy.com/north
-
carolina
-
large
-
business/energy
-
efficiency/nclb
-
smart
-
saver
-
incentives.asp

>
Energy Footprints by NAICS Codes


www1.eere.energy.gov/manufacturing/pdfs/mfg_footprint_2012.pdf

>
Energy Star


www.energystar.gov/index.cfm?c=business.bus_index

>
Electric Power Research Institute (EPRI)


www.epri.com/Pages/Default.aspx

▫
Melting Technologies for Aluminum and other Non
-
ferrous metals
–

EPRI Technical Commentary
–
Product Id:1001025, 2000

▫
Induction and Cupola Melting: A cost comparison model: CR
-
108697, CMP
–

Report No 89
-
4, 1989

▫
Efficient Electric Technologies for Industrial Heating, product Id
–

1014000, 2007

▫
Good Practice Guide 50
–

Efficient Melting in Coreless Induction Furnaces, 2000

▫
Ind Heat WS Code
-

Cost Comparison Worksheet for Induction Heating, Version 1.0, EPRI Product Id:
1001500, May
2001


Copyright ©
2013,

North Carolina Advanced Energy Corporation. All rights reserved.

Sources


INFORMATION SOURCES (continued):

>
Industrial Heating Equipment Association (IHEA)


www.ihea.org

>
Inductotherm


www.inductotherm.com/index.htm

>
ISO 50001
–

Energy Management System


www.eere.energy.gov/energymanagement

>
Powerit
Solutions


www.poweritsolutions.com/

>
Superior Energy Performance Overview


www.superiorenergyperformance.net/

>
Superior Energy Performance Demonstration


www.eere.energy.gov/industry/energymanagementdemonstrations/

>
Theoretical/Best Practice Energy Use in Metalcasting Operations


J.F. Schifo, J.T. Radia, KERAMIDA Environmental, Inc., Indianapolis, IN, 2004

Copyright ©
2013,

North Carolina Advanced Energy Corporation. All rights reserved.

Questions

ENDURING

TRANSFORMATION
with an ever increasing
OUTPUT

per unit of
INPUT

Michael Stowe

(919) 857
–

9043 {desk}

(919) 904
–

0279 {cell}

mstowe@advancedenergy.org

Energy Efficiency in Foundries and Melting