I. Energy / Utilities
A. Electricity
1. Consumption per gross pound melted = .3972 kwh / gross lbs melted
2. Cost per KWH = .0639$/kwh
3. Adjusted for Yield.
4. Electricity costs per ton and pound
a. 2010 = (2000 lbs x .3971 kwh/gr lb melted) x .0639$/kwh = $50.75 / Gr ton melted
b. Adjusted for yield to get to $/net pound
c. If a customer’s yield is higher or lower, it will have a significant impact and will be adjusted for accordingly.
B. Natural Gas
1. Dollar consumption per gross pound melted = .0042$ / gross lbs.
a. Adjusted for yield
b. If a customer’s yield is higher or lower, it will have a significant impact and will be adjusted for accordingly.
C. Coke – Cupola Shop = $396 / nt purchased
a. Adjusted for yield
b. If a customer’s yield is higher or lower, it will have a significant impact and will be adjusted for accordingly.
c. Coke is the primary energy source in a cupola melt operation, independent of the electricity required for the holding furnace. Increased cost is reflected in a “charge” cost calculation. (See charge cost January 4, 2010 below).
D. Water / Sewer = .0042$ / gal
a. Adjusted for yield
b. If a customer’s yield is higher or lower, it will have a significant impact and will be adjusted for accordingly.
E. Energy total
a. Electricity
b. Natural Gas
c. Charge Coke
d. Water / Sewer
e. If a customer’s yield is higher or lower, it will have a significant impact and will be adjusted for accordingly.
II. Disposal Costs – Consumption per gross lb melted = .0034$/gross lb
a. Adjusted for yield
b. If a customer’s yield is higher or lower, it will have a significant impact and will be adjusted for accordingly.
III. Pre-charge cost calculation / Disposal and Energy
a. Energy total
b. Disposal total
c. If a customer’s yield is higher or lower, it will have a significant impact and will be adjusted for accordingly.
IV. Charge calculations – Base Year January 4, 2010 (See Link)
V. Total surcharge adjustment since base Year 2010.
a. Charge cost increase.
b. Environmentals & Disposal Increase
c. Energy Cost Increase
Subtotal
d. If a customer’s yield is higher or lower, it will have a significant impact and will be adjusted for accordingly.
VI. It should be noted by all, that under the Obama Administration, all of the above costs will only increase dramatically for many years to come.
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SURCHARGE CALCULATION
January 1, 2010
| CLASS 25 | CLASS 30 | |||||||
| COST | COST | COST | ||||||
| PER LB | % | LBS. | PER NT | % | LBS. | PER NT | ||
| COST | 2041.60 | |||||||
| RETURNS | 195.61 NT | 0.098 | 45.00% | 900.00 | 88.20 | 44.06% | 881.28 | 86.37 |
| BASIC PIG IRON | 336.00 NT | 0.168 | 12.00% | 240.00 | 40.32 | 11.75% | 235.01 | 39.48 |
| Foundry Pig | - NT | 0.000 | - | - | 0.00% | 0.00 | - | |
| MOTOR BLOCK | 225.00 GT | 0.100 | 43.00% | 860.00 | 86.38 | 42.11% | 842.11 | 84.59 |
| COKE | 396.00 NT | 0.198 | 285.00 | 56.43 | 0.00% | 285.00 | 56.43 | |
| LIMESTONE | 14.00 NT | 0.007 | 95.00 | 0.67 | 95.00 | 0.67 | ||
| 50% SILICON BRICK | 486.00 NT | 0.243 | 36.00 | 8.75 | 36.00 | 8.75 | ||
| CARBON/GRAPHITE | 1,060.00 NT | 0.530 | 4.00 | 2.12 | 4.00 | 2.12 | ||
| MANGANESE BRICK | 1,249.00 NT | 0.625 | 1.50 | 0.94 | 1.50 | 0.94 | ||
| STEEL | 484.00 GT | 0.216 | - | 2.00% | 40.00 | 8.64 | ||
| FERRO MOLY | - LB | - | 0.00 | - | ||||
| INOCUCHROME | 0.91 LB | 0.910 | 0.00% | 0.00 | - | |||
| TIN | 7.35 LB | 7.350 | - | 0.08% | 1.60 | 11.76 | ||
| 100.00% | 100.00% | |||||||
| COST PER NET TON | 195.61 | 213.38 | ||||||
| COST PER NET TON WITH RETURNS | 283.81 | 299.75 | ||||||
_________________________________________________________________
| CLASS Super 30 | CLASS 35 | |||||||
| COST | COST | COST | ||||||
| PER LB | % | LBS. | PER NT | % | LBS. | PER NT | ||
| COST | 2001.60 | 2051.60 | ||||||
| RETURNS | 195.61 NT | 0.098 | 44.96% | 899.28 | 88.13 | 43.84% | 876.78 | 85.92 |
| BASIC PIG IRON | 336.00 NT | 0.168 | 11.99% | 239.81 | 40.29 | 11.69% | 233.81 | 39.28 |
| Foundry Pig | - NT | 0.000 | 0.00% | 0.00 | - | 0.00% | 0.00 | - |
| MOTOR BLOCK | 225.00 GT | 0.100 | 42.97% | 859.31 | 86.31 | 41.89% | 837.81 | 84.15 |
| COKE | 396.00 NT | 0.198 | 0.00% | 255.00 | 50.49 | 0.00% | 285.00 | 56.43 |
| LIMESTONE | 14.00 NT | 0.007 | 95.00 | 0.67 | 95.00 | 0.67 | ||
| 50% SILICON BRICK | 486.00 NT | 0.243 | 32.00 | 7.78 | 36.00 | 8.75 | ||
| CARBON/GRAPHITE | 1,060.00 NT | 0.530 | 0.00 | - | 4.00 | 2.12 | ||
| MANGANESE BRICK | 1,249.00 NT | 0.625 | 1.50 | 0.94 | 1.50 | 0.94 | ||
| STEEL | 484.00 GT | 0.216 | 0.00% | 0.00 | - | 2.00% | 40.00 | 8.64 |
| FERRO MOLY | - LB | 0.00 | - | 0.00% | 0.00 | - | ||
| INOCUCHROME | 0.91 LB | 0.910 | 0.00% | 0.00 | - | 0.50% | 10.00 | 9.10 |
| TIN | 7.35 LB | 7.350 | 0.08% | 1.60 | 11.76 | 0.08% | 1.60 | 11.76 |
| 100.00% | 100.00% | |||||||
| COST PER NET TON | 198.24 | 221.84 | ||||||
| COST PER NET TON WITH RETURNS | 286.37 | 307.76 | ||||||
_________________________________________________________________
| CLASS 40 | |||||
| COST | COST | ||||
| PER LB | % | LBS. | PER NT | ||
| COST | 2051.6 | ||||
| RETURNS | 195.61 NT | 0.098 | 43.84% | 876.78 | 85.92 |
| BASIC PIG IRON | 336.00 NT | 0.168 | 11.69% | 233.81 | 39.28 |
| Foundry Pig | - NT | 0.000 | 0.00% | 0.00 | - |
| MOTOR BLOCK | 225.00 GT | 0.100 | 41.89% | 837.81 | 84.15 |
| COKE | 396.00 NT | 0.198 | 0.00% | 285.00 | 56.43 |
| LIMESTONE | 14.00 NT | 0.007 | 95.00 | 0.67 | |
| 50% SILICON BRICK | 486.00 NT | 0.243 | 36.00 | 8.75 | |
| CARBON/GRAPHITE | 1,060.00 NT | 0.530 | 4.00 | 2.12 | |
| MANGANESE BRICK | 1,249.00 NT | 0.625 | 1.50 | 0.94 | |
| STEEL | 484.00 GT | 0.216 | 1.50% | 30.00 | 6.48.64 |
| FERRO MOLY | - LB | 0.00% | 0.00 | - | |
| INOCUCHROME | 0.91 LB | 0.910 | 1.00% | 20.00 | 18.20 |
| TIN | 7.35 LB | 7.350 | 0.08% | 1.60 | 11.76 |
| 100.00% | |||||
| COST PER NET TON | 228.78 | ||||
| COST PER NET TON WITH RETURNS | 314.70 | ||||

