Equipment Highlight: Investment in Energy-Efficient Furnace Pays Off

energySMART Aluminum Furnace

Chicago White Metal is always looking for ways to improve the die casting process while decreasing energy usage. Back in 2014, CWM determined that one of the best ways to accomplish both of those goals was to replace our old reverberatory furnace from the 1970s with a modern central stackmelter aluminum furnace.

CWM worked with energySMART, a Nicor Gas program, to replace our underperforming furnace with a high-efficiency one. After much deliberation, CWM chose the StrikoMelter furnace from StrikoWestofen America because it offered the lowest energy consumption of any furnace in its class.

Energy Efficiency & Improved Performance

When CWM chose the StrikoWestofen energy-efficient aluminum melting furnace, we immediately received energySMART incentives in return for reducing our carbon footprint. With the new furnace, CWM cut the amount of natural gas we used in the melting process substantially. And even though the StikoMelter came with a smaller holding capacity, the melting capacity significantly increased to 4,400 lbs. per hour instead of 1,400 lbs. per hour with the old furnace.

By acquiring the modern furnace, CWM qualified for the Nicor Gas Energy Efficiency Program, an energy-purchase rebate program funded by Nicor Gas Company. The incentives from this program enabled CWM to make the investment, which saw immediate returns.

How it works:

The new furnace came with Striko’s patented ETAmax® system, which combines preheating, heating, and melting phases efficiently in a single melting shaft. While return material and ingots are melted quickly in the lower section, the material preheats in the shaft area above it.

The molten metal is then transferred to a holding bath, reducing waste and maintaining preset holding temperature. This simple but effective recuperative concept resulted in significant fuel consumption savings and a dramatic reduction in metal loss due to oxidation or dross. Other benefits of having a modern, energy-efficient furnace include:

  • Easy to load: The furnace’s shaft is more expansive and can easily accept returns of up to 2.5m². Extra-large charging bins also mean there’s no need to “cut to fit,” saving precious time, resources, and money.
  • Less energy wasted: Shortened metal melting, reduced natural gas consumption, and an improved material yield to increase efficiency.
  • Cleaner metal: The design of the furnace limits the amount of dross and oxide production resulting in cleaner metal and less waste.

Looking back almost seven years to the date, we can say that it was well worth the investment when it comes to energy savings and improving CWM’s overall product. When asked about the furnace, Jim Reitenbach, Production Manager at CWM, said, “This was one of the best equipment investments CWM has ever made.”

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