United Cast Bar Ltd.

Representatives from National Grid visited United Cast Bar UK (UCB), the leading foundry and a successful manufacturer of continuously cast-iron bar. UCB uses GridBeyond’s energy intelligence platform to support grid balancing, increase profitability and boost sustainability.

The purpose of the meeting at the production plant in Chesterfield was for National Grid to observe manufacturing processes and witness first-hand how smart sensors and intelligent energy technology provides UCB full visibility and control of their energy usage whilst enabling participation in DSR programmes. The latter ultimately supports the system operator’s mission to maintain a smart, resilient, decentralised and flexible energy network.

UCB’s most power intensive assets include melt furnaces, which constitute the core of the foundry business. These deliver approx. 1.9 Megawatts of flexibility to the grid, without any impact on operations. UCB’s energy flexibility and operational integrity is further enhanced by GridBeyond’s hybrid battery & demand network, a unique and world-first solution which unlocks additional energy flexibility from the inflexible assets. 

UCB participate in several DSR programmes, including the fast responding Dynamic Firm Frequency Response (DFFR), and uses an on-site 500kW battery to lower the energy consumption during peak demand.

Through the summer of 2018, project and system design began for the installation of new extraction system in our Spanish Foundry, Cast Profil. Stricter guidelines and controls are being required for manufacturing businesses like UCB, for cleaner and safer operating environments.

The new system was designed and built by a specialised manufacturer from Germany with more than 75 years of work experience in the construction of air pollution control systems – Luehr Filter. Based on our specifications they were able to develop a process-related solution that totally meets current and potential future regulations on dust and noise pollution. Luehr Filter has been supported by the Spanish company IMIG in the construction and initialisation of the equipment.

During the December holidays, the new extraction system was installed, in time and on schedule for the New Year start up in January.

“We are really pleased to have worked with such a strong International Partner for the design and implementation of this system. We have achieved a significant improvement in the working environment and can hope to meet and exceed the future environmental standards.” (James Brand, Foundries Director UCB)

During 2017, UCB began looking to take energy resilience to a new level. It was becoming increasingly necessary to consider revolutionary ideas and strategies to overcome growing energy obstacles for our foundry in Chesterfield, UK.

Maintaining our reputation as the vanguard for energy management within metal manufacturing, United Cast Bar (UK) collaborated with GridBeyond to deliver a solution to energy challenges through technology, helping to balance energy demand and satisfy our environmental commitment without any  impact on our operations.

With GridBeyond and their partner EBS Smart Energy Services investing, installing and implementing the Project, UCB (UK) became the first metal production site in the UK to have a battery installation 'behind the meter'.

The newly installed 500kW TESLA battery storage solution enables UCB (UK) not just to participate in National Grid`s Dynamic Frequency Response (DFR) program but also to avoid ever growing Peak Charges, monitor and analyse energy consumption patterns whilst reducing our carbon footprint.