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

Industrial Assessment Centers

Assessment #BD0346


Assessment Year 2008
SIC 3366
SIC Description Copper Foundries
NAICS 331525
NAICS Description Copper Foundries (except Die-Casting)
Principal Product water and Natural Gas Flow Products
Sales $ 1,000,000
# of Employees 300
Plant Area (Sq.Ft.) 280,000
Annual Production 10,000,000 Not Available
Production Hrs. Annual 2,600
Location (State) IL
Yearly Energy Cost $ 2,189,835

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 27,439,179 kWh $ 1,332,125 $ 0.049 /kWh

- Demand Charge

 68,203 kW $ 105,962 $ 1.55 /kW

- Electricity Fees

 - $ 114,536 -

Natural Gas

 78,255 MMBtu $ 637,212 $ 8.14 /MMBtu

TOTAL ENERGY

 359,507 MMBtu $ 2,189,835 $ 6.09 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 2,394,188 kWh
2,299,922 kWh		 $ 135,751
$ 130,406		 10.19 %
9.79 %		 $ 0.049 /kWh

- Demand Charge

 3,623 kW
3,435 kW		 $ 3,437
$ 3,259		 3.24 %
3.08 %		 $ 1.55 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 7,478 MMBtu
0 MMBtu		 $ 60,890
$ 0		 9.56 %
0.00 %		 $ 8.14 /MMBtu

TOTAL ENERGY

 32,019 MMBtu
23,574 MMBtu		 $ 200,078
$ 133,665		 9.14 %
6.10 %		 $ 6.09 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 2,972 $ 84,447 0.04
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 1,452,995 kWh $ 82,386 $ 0.049 /kWh

- Demand Charge

 2,172 kW $ 2,061 $ 1.55 /kW

TOTAL ENERGY

 14,893 MMBtu $ 84,447 -
02 view
details		 INSTALL OCCUPANCY SENSORS 2.7135 N $ 676 $ 1,472 0.46
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 25,249 kWh $ 1,432 $ 0.049 /kWh

- Demand Charge

 42 kW $ 40 $ 1.55 /kW

TOTAL ENERGY

 259 MMBtu $ 1,472 -
03 view
details		 UTILIZE DAYLIGHT WHENEVER POSSIBLE IN LIEU OF ARTIFICIAL LIGHT 2.7121 N $ 4,569 $ 4,548 1.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 58,979 kWh $ 3,344 $ 0.049 /kWh

- Demand Charge

 131 kW $ 124 $ 1.55 /kW

TOTAL ENERGY

 605 MMBtu $ 3,468 -

Personnel Changes

 - $ 831 -

Primary Raw Material

 - $ 249 -

TOTAL PRODUCTON

 - $ 1,080 -
04 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 N $ 1,366 $ 893 1.53
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 10,038 kWh $ 569 $ 0.049 /kWh

- Demand Charge

 15 kW $ 14 $ 1.55 /kW

TOTAL ENERGY

 103 MMBtu $ 583 -

Personnel Changes

 - $ 130 -

Primary Raw Material

 - $ 180 -

TOTAL PRODUCTON

 - $ 310 -
05 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 10,001 $ 48,385 0.21
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 834,183 kWh $ 47,298 $ 0.049 /kWh

- Demand Charge

 1,146 kW $ 1,087 $ 1.55 /kW

TOTAL ENERGY

 8,550 MMBtu $ 48,385 -
06 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 I $ 501 $ 833 0.60
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 12,744 kWh $ 722 $ 0.049 /kWh

- Demand Charge

 117 kW $ 111 $ 1.55 /kW

TOTAL ENERGY

 131 MMBtu $ 833 -
07 view
details		 REPLACE BOILER 2.1224 N $ 65,001 $ 37,675 1.73
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 4,627 MMBtu $ 37,675 $ 8.14 /MMBtu

TOTAL ENERGY

 4,627 MMBtu $ 37,675 -
08 view
details		 DIRECT WARMEST AIR TO COMBUSTION INTAKE 2.1213 N $ 1,251 $ 4,096 0.31
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 503 MMBtu $ 4,096 $ 8.14 /MMBtu

TOTAL ENERGY

 503 MMBtu $ 4,096 -
09 view
details		 USE RADIANT HEATER FOR SPOT HEATING 2.7231 N $ 14,001 $ 19,119 0.73
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 2,348 MMBtu $ 19,119 $ 8.14 /MMBtu

TOTAL ENERGY

 2,348 MMBtu $ 19,119 -