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

Industrial Assessment Centers

Assessment #AM0591


Assessment Year 2011
SIC 2891
SIC Description Adhesives And Sealants
NAICS 325520
NAICS Description Adhesive Manufacturing
Principal Product Phenolic resins, formaldehyde, wax
Sales $ 60,000,000
# of Employees 40
Plant Area (Sq.Ft.) 100,000
Annual Production 95,750 Tons
Production Hrs. Annual 7,200
Location (State) TX
Yearly Energy Cost $ 492,070

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 4,215,600 kWh $ 191,599 $ 0.045 /kWh

- Demand Charge

 8,208 kW $ 64,921 $ 7.91 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 46,600 MMBtu $ 235,550 $ 5.05 /MMBtu

TOTAL ENERGY

 89,810 MMBtu $ 492,070 $ 5.48 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 910,130 kWh
62,080 kWh		 $ 50,060
$ 3,410		 26.13 %
1.78 %		 $ 0.045 /kWh

- Demand Charge

 1,661 kW
1,623 kW		 $ 11,175
$ 10,925		 17.21 %
16.83 %		 $ 7.91 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 -2,966 MMBtu
3,284 MMBtu		 $ -14,790
$ 17,010		 -6.28 %
7.22 %		 $ 5.05 /MMBtu

TOTAL ENERGY

 6,363 MMBtu
3,920 MMBtu		 $ 46,445
$ 31,345		 9.44 %
6.37 %		 $ 5.48 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 MINIMIZE WATER USAGE 3.4151 N $ 80,000 $ 141,000 0.57
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 -6,250 MMBtu $ -31,800 $ 5.05 /MMBtu

TOTAL ENERGY

 -6,250 MMBtu $ -31,800 -

Water Disposal

 7,200,000 Gal $ 172,800 $ 0 /Gal

TOTAL WASTE

 - $ 172,800 -
02 view
details		 INSULATE BARE EQUIPMENT 2.2511 N $ 13,800 $ 42,800 0.32
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 778,900 kWh $ 42,800 $ 0.045 /kWh

TOTAL ENERGY

 7,984 MMBtu $ 42,800 -
03 view
details		 OPTIMIZE PLANT POWER FACTOR 2.3212 I $ 15,900 $ 10,060 1.58
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Demand Charge

 1,490 kW $ 10,060 $ 7.91 /kW

TOTAL ENERGY

 0 MMBtu $ 10,060 -
04 view
details		 REPAIR AND ELIMINATE STEAM LEAKS 2.2135 I $ 5,000 $ 9,540 0.52
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,834 MMBtu $ 9,540 $ 5.05 /MMBtu

TOTAL ENERGY

 1,834 MMBtu $ 9,540 -
05 view
details		 REPAIR OR REPLACE STEAM TRAPS 2.2113 I $ 1,300 $ 5,270 0.25
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,013 MMBtu $ 5,270 $ 5.05 /MMBtu

TOTAL ENERGY

 1,013 MMBtu $ 5,270 -
06 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 4,290 $ 2,275 1.89
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 32,700 kWh $ 1,800 $ 0.045 /kWh

- Demand Charge

 59 kW $ 365 $ 7.91 /kW

TOTAL ENERGY

 335 MMBtu $ 2,165 -

Ancillary Material Cost

 - $ 110 -

TOTAL PRODUCTON

 - $ 110 -
07 view
details		 INSULATE BARE EQUIPMENT 2.2511 I $ 950 $ 2,200 0.43
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 437 MMBtu $ 2,200 $ 5.05 /MMBtu

TOTAL ENERGY

 437 MMBtu $ 2,200 -
08 view
details		 INSULATE BARE EQUIPMENT 2.2511 N $ 950 $ 2,130 0.45
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 37,850 kWh $ 2,130 $ 0.045 /kWh

TOTAL ENERGY

 388 MMBtu $ 2,130 -
09 view
details		 MAKE A PRACTICE OF TURNING OFF LIGHTS WHEN NOT NEEDED 2.7124 I $ 325 $ 1,800 0.18
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 23,700 kWh $ 1,300 $ 0.045 /kWh

- Demand Charge

 74 kW $ 500 $ 7.91 /kW

TOTAL ENERGY

 243 MMBtu $ 1,800 -
10 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 N $ 0 $ 1,500 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 22,700 kWh $ 1,250 $ 0.045 /kWh

- Demand Charge

 38 kW $ 250 $ 7.91 /kW

TOTAL ENERGY

 233 MMBtu $ 1,500 -
11 view
details		 INSTALL SKYLIGHTS 2.7145 N $ 0 $ 470 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 8,600 kWh $ 470 $ 0.045 /kWh

TOTAL ENERGY

 88 MMBtu $ 470 -
12 view
details		 CLOSE HOLES AND OPENINGS IN BUILDING SUCH AS BROKEN WINDOWS 2.7444 I $ 170 $ 310 0.55
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 5,680 kWh $ 310 $ 0.045 /kWh

TOTAL ENERGY

 58 MMBtu $ 310 -