In an effort to keep the metalcasting industry abreast of the latest developments and savings opportunities relating to energy, AFS will be producing an energy webinar series. With the exception of Module 1, which will be free, each session will be available for purchase as single or a group of modules, and will include:

Module 1  
Getting Started: Understanding the Issues
Broadcast date: May 12, 2009

1.1 Energy, the Hidden Cost      
This section will cover the true cost of energy in the foundry and the effect of energy reduction on profitability. Mod 1.1 will define the importance of measuring energy use and the most important factors in reduction. (Bob Eppich, Eppich Technologies)
1.2 CEO Briefing: Why you must be concerned about energy
Mod 1.2 defines the danger of inaction. Energy reduction is a risk management procedure. Energy costs have significantly increased in recent years, but a peak into the future reveals market forces and government policies that can lead to an explosion of energy costs. The profitability of your foundry is at risk if energy consumption is not controlled. (Redmond Clark, CCL Industrial Services / TDJ Group)
1.3 AFS Energy Solutions: Cost Savings Opportunities
An overview of AFS services to help the foundry industry reduce energy. Energy solutions include a review of your energy bill, help with procurement and other opportuinitie4s to reduce energy consumption.  (Leo Baran, AFS; Brian Reinke, TDI Consulting Inc)

Module 2
Utilities
Broadcast date: May 14, 2009

2.2 Natural Gas Energy Costs: A review of natural gas reserves, supplies, market drivers, potential supply source disruptions and price forecasts. (Redmond Clark, CBL Industrial Services / TDJ Group)
2.3 Electric Energy Cost-Saving Opportunities and Successes: Review of electric rate structures, effect of deregulation, electric industry restructuring, demand controllers, price forecasts and market drivers. Understanding your electric bill.

Module 3
Controlling Ferrous Melting Costs
Broadcast date: May 19, 2009

3.1 Induction Melting: Mod 3.1 will help establish best practices for induction melting, with emphasis on practical, shop floor issues including: operating procedures, maintenance, charge materials. This module will also include advice how to measure your energy consumption and managing electricity use through rate structures, peak/off peak hours, ratchet, penalties, etc. (Robert Keshecki, Inductotherm)
3.2 Cupola Melting: A practical module on measuring and controlling energy during cupola melting, including natural gas pricing, electrical needs, coke, compressed air, refractory lining, gas recuperators, air exchangers, PLC controls and the effect of cupola maintenance. (Dave Kasun, Kuntner Modern)
3.4 Holding ladles: New methods for preheating transfer and pouring ladles in iron melting. (Kent Peaslee, Missouri University of Science and Technology) 
3.5 Melt Cost Reduction through Power Curtailment
CASE STUDY: How one foundry has managed their melt cost through the use of demand controllers, APS Zone, Locational Marginal Pricing, and other electric grid management opportunities. (Walt Matthews, T B Wood's Inc.)
      
Module 4
Controlling Non-Ferrous Melting Costs
Broadcast date: May 21, 2009

4.1 Gas Fired Melting: Mod 4.1 will provide information of how to calculating the cost of melting as well as practical advise on shop floor melting procedures, preheating ingot, cost of open bath, refractory choice and installation, materials, care and maintenance, holding and transfer. The presentations will cover reverbs, stack melting and gas-fired crucible furnaces. Energy myths and realities will be discussed. (David.White, The Schaefer Group)
4.2 Crucible Furnaces/Electric Resistance Furnaces: This mod is designed to help the aluminum foundries save energy in electric resistance melting by providing tools to them save energy proper management of the furnace equipment and process controls. Presentation will discuss furnace covers, holding vs. batch melting, retrofit additions, improved process control procedures, new furnace models, transfer furnaces and ladles. Presentation will provide a comparison of gas and electric melting. (Ted Kostilnik, Morgan Molten Metal Systems).
4.4 Heat Recuperation and Recycling: New technologies that can reduce energy through recuperation and recycling furnace flue heat in gas fired crucible and reverb furnaces. Equipment can be retrofitted to current melting furnaces. (Jim Roberts, Eclipse Innovative thermal Solutions)

Module 5
Managing Compressed Air Systems
Broadcast date: May 26, 2009 

Module 5 will help the foundry reduce the cost of operating air compressors. Practice help for calculating the actual cost of compressed air, determining demand, designing a cost effective system, cost of air dryers, cost of air leaks and air vs. electric tools. Presentation will include foundry case studies. (David Kehrer, Brabazon Engineered Systems & Technologies)

Module 6
Plant Environment and Equipment
Broadcast date: May 28, 2009

6.1 Shop Lighting and Heating: Significant opportunity exists to reduce energy consumption through control of plant lighting and plant/office HVAC. Case studies will demonstrate actual cost saving in metalcasting operations. Presentation will include information on demand controllers, motion sensors and plant heating and cooling systems. (Dave Riggle, Energy Management Systems)
6.2 Ventilation: Module will discuss energy cost saving through the control of ventilation systems. Presentation will include calculating ventilation need to properly size the system. (Gerry Lanham, KBD/Technic, Inc.)
6.3 Electric motors: Reduce cost through effective use of electric motors. Calculate how much horse power you need, Presentation will cover the types of motor options, the value of high efficiency motors, choosing between rewinding or purchasing a new motor, properly sizing motor for the job, measuring output need and electric motor use during non-production hours. (Neal Elliott, American Council for an Energy-Efficient Economy).
6.4 Demand controllers for melting: Reduce energy use through effective use of demand control. Practical foundry examples will be included. (Bob Zak and Stephanie Jewell, Powerit Solutions, Inc.)
     
Module 7
Implementation: Assessments and Best practices
Broadcast date: June 4, 2009

Module 7 will provide resources to measure energy use, conduct energy assessments and potential funding opportunities for installation of energy saving equipment.  Module will also provide additional opportunities for training and information resources. 

Modules 2-7 will be available individually or as a package (the first module is free). Single modules are $99, two modules are $175, 3 modules are $250 and the entire package is $350. For more information on the Energy Savings Webinar Series, contact Becky Erickson, AFS technical assistant, at 800/537-4237 x 246 or This e-mail address is being protected from spam bots, you need JavaScript enabled to view it .