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U.S. Department of Energy Energy Efficiency and Renewable Energy
IAC Field Managers

Industrial Assessment Centers

Assessment #AM0575


Assessment Year 2010
SIC 3291
SIC Description Abrasive Products
NAICS 327999
NAICS Description All Other Miscellaneous Nonmetallic Mineral Product Manufacturing
Principal Product Abrasives
Sales $ 84,000,000
# of Employees 460
Plant Area (Sq.Ft.) 325,000
Annual Production 240,000,000 Pieces
Production Hrs. Annual 6,000
Location (State) TX
Yearly Energy Cost $ 849,462

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 9,908,849 kWh $ 682,875 $ 0.069 /kWh

- Demand Charge

 25,747 kW $ 148,406 $ 5.76 /kW

- Electricity Fees

 - $ 18,181 -

TOTAL ENERGY

 101,567 MMBtu $ 849,462 $ 8.36 /MMBtu

Recommended Reduction in Usage & Costs

Recommended
Implemented
Energy Sources Yearly Savings Yearly Cost % Saved Unit Price

Electricity

 1,863,680 kWh
831,080 kWh		 $ 129,455
$ 57,705		 18.96 %
8.45 %		 $ 0.069 /kWh

- Demand Charge

 7,698 kW
1,703 kW		 $ 45,553
$ 10,075		 30.69 %
6.79 %		 $ 5.76 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

TOTAL ENERGY

 19,103 MMBtu
8,519 MMBtu		 $ 175,008
$ 67,780		 20.60 %
7.98 %		 $ 8.36 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 5,000 $ 64,600 0.08
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 795,000 kWh $ 55,200 $ 0.069 /kWh

- Demand Charge

 1,589 kW $ 9,400 $ 5.76 /kW

TOTAL ENERGY

 8,149 MMBtu $ 64,600 -
02 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 N $ 78,700 $ 46,350 1.70
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 570,000 kWh $ 39,600 $ 0.069 /kWh

- Demand Charge

 1,140 kW $ 6,750 $ 5.76 /kW

TOTAL ENERGY

 5,843 MMBtu $ 46,350 -
03 view
details		 INSTALL OCCUPANCY SENSORS 2.7135 N $ 9,350 $ 20,350 0.46
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 225,200 kWh $ 15,650 $ 0.069 /kWh

- Demand Charge

 793 kW $ 4,700 $ 5.76 /kW

TOTAL ENERGY

 2,308 MMBtu $ 20,350 -
04 view
details		 RE-ARRANGE EQUIPMENT LAYOUT TO REDUCE LABOR COSTS 4.513 N $ 170,000 $ 18,870 9.01
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 29,800 kWh $ 2,070 $ 0.069 /kWh

TOTAL ENERGY

 305 MMBtu $ 2,070 -

Personnel Changes

 - $ 16,800 -

TOTAL PRODUCTON

 - $ 16,800 -
05 view
details		 OPTIMIZE PLANT POWER FACTOR 2.3212 N $ 54,200 $ 18,400 2.95
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Demand Charge

 3,111 kW $ 18,400 $ 5.76 /kW

TOTAL ENERGY

 0 MMBtu $ 18,400 -
06 view
details		 INSTALL SKYLIGHTS 2.7145 N $ 68,500 $ 13,790 4.97
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 198,400 kWh $ 13,790 $ 0.069 /kWh

TOTAL ENERGY

 2,034 MMBtu $ 13,790 -
07 view
details		 OPTIMIZE PLANT POWER FACTOR 2.3212 N $ 8,520 $ 5,523 1.54
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Demand Charge

 933 kW $ 5,523 $ 5.76 /kW

TOTAL ENERGY

 0 MMBtu $ 5,523 -
08 view
details		 MAKE A PRACTICE OF TURNING OFF LIGHTS WHEN NOT NEEDED 2.7124 I $ 450 $ 2,950 0.15
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 33,140 kWh $ 2,300 $ 0.069 /kWh

- Demand Charge

 110 kW $ 650 $ 5.76 /kW

TOTAL ENERGY

 340 MMBtu $ 2,950 -
09 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 460 $ 1,000 0.46
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 2,940 kWh $ 205 $ 0.069 /kWh

- Demand Charge

 4 kW $ 25 $ 5.76 /kW

TOTAL ENERGY

 30 MMBtu $ 230 -

Ancillary Material Cost

 - $ 770 -

TOTAL PRODUCTON

 - $ 770 -
10 view
details		 USE SYNTHETIC LUBRICANT 2.4314 N $ 0 $ 745 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 9,200 kWh $ 640 $ 0.069 /kWh

- Demand Charge

 18 kW $ 105 $ 5.76 /kW

TOTAL ENERGY

 94 MMBtu $ 745 -