1. Wisconsin Foundry Industry Overview 125 foundries 80% - 100 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

2. 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

3. 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

4. Energy Use Profile – Cupola Shop APC/AMU

5. 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

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

7. 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”

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

9. 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

10. 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)