Wisconsin Foundry Industry Overview 125 foundries 80% employees or less 21,000 employees Payroll $870 million $3.5 billion in sales Wisconsin 3d Ranked Foundry State Nationally 200 – 250 trillion Btu per year

WCMA Energy Initiatives Focus on education and facilitation Incorporated energy issues into the standing Environmental Committee Best Practices Handbook & May 2006 Workshop Targeted Site Assessments – future Regional Workshops No goal set to date

Foundry Industry – Barriers to Energy Reduction International competition – priority is survival and market-share. Capital priorities. Demographics  internal resources (many hats for one individual) Environmental requirements – air pollution control

Energy Use Profile – Cupola Shop APC/AMU

Foundry Support Small Foundries will require more individual attention and financial assistance Large Foundries continued financial incentives and tax credits All require education/awareness and research/development

Assistance Model Research *AFS * Universities Local Foundry Focus on Energy WCMA DOE – Industrial Technologies Program

Assistance Considerations Existing model is effective Do not forget about the basics Do not assume that a 2 year pay back is a “slam dunk”

Historical Practices Scrap recycling  life cycle perspective Sand recycling  life cycle perspective Preheat of cupola blast air (1980) Inductor and furnace efficiency Purchasing practices

Recent Energy Reduction Activities Compressor system modifications and control Cupola heat recovery for space heat  50,000 dekatherm annual savings Lighting Projects  $325K invested to date Premium efficiency motor project

Future Reduction Activities HVAC smart building controls Plant 1 Cupola Heat Recovery Compressor System Retrofits Lighting Retrofits Waste Heat to Electricity  8 MW (long term 6 –8 year payback)