Day by day the electrical energy consumption is increased to meet the customer demand like new industries development, electric vehicle charging, railway development and raise in population increase etc. Though variable renewable energy resources are added to meet out the demand and reduce greenhouse emission with less carbon di oxide it is necessary to reduce the power consumption of the existing industry for the same productivity to avoid pollution and global warming. The proposed system works on the principle of energy saving is nothing but energy production which optimize the power consumption for the same quantity of production, reduces CO2 emission and reduce the cost of production which increases the profit of the industry. By optimizing the electrical energy conservation, the Green House Emission pollutant gases like CO2, Methane, Nitrous Oxide, Sulfur Hexafluoride etc… also reduces from the thermal or atomic electrical power generation which reduce global warming and climate change. Induction furnaces of plant for melting metal are the major power consuming equipment in foundry industries and by providing effective power management system to multiple furnaces and utilizing the power in an optimized way increases the furnace liquid metal productivity and share the energy throughout the plant in an optimized way which eliminates maximum demand penalty by the electricity board during billing and reduces power consumption per tonnage of liquid metal produced which increase the profit of the plant and reduce global warming. In the proposed power management system the power consumption of a foundry is utilized in such a way that when the power of a furnace is utilized less the standard capacity due to operational constraints and production status, the unutilized power from the furnace is fed to the other furnaces of the industry without affecting the safety and quality of the liquid metal produced by the furnaces since abnormal sudden raise in furnace power may lead to liquid metal burst during slag removal and controlled temperature raise of liquid metal for pouring operation.
