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

Industrial Assessment Centers

Assessment #DL0062


Assessment Year 2010
SIC 2836
SIC Description Biological Products Exc. Diagnostic
NAICS 325414
NAICS Description Biological Product (except Diagnostic) Manufacturing
Principal Product Animal Vaccines
Sales $ 1,000,000
# of Employees 300
Plant Area (Sq.Ft.) 94,000
Annual Production 6 Thousand Gallons
Production Hrs. Annual 8,766
Location (State) DE
Yearly Energy Cost $ 1,874,934

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 14,389,115 kWh $ 1,511,947 $ 0.105 /kWh

- Electricity Fees

 - $ 0 -

Natural Gas

 31,691 MMBtu $ 362,987 $ 11.45 /MMBtu

TOTAL ENERGY

 179,179 MMBtu $ 1,874,934 $ 10.46 /MMBtu

Water Disposal

 35,356,294 Gal $ 31,821 $ 0 /Gal

Recommended Reduction in Usage & Costs

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

Electricity

 409,552 kWh
74,000 kWh		 $ 43,782
$ 7,900		 2.90 %
0.52 %		 $ 0.105 /kWh

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 2,529 MMBtu
0 MMBtu		 $ 22,300
$ 0		 6.14 %
0.00 %		 $ 11.45 /MMBtu

TOTAL ENERGY

 6,726 MMBtu
758 MMBtu		 $ 66,082
$ 7,900		 3.52 %
0.42 %		 $ 10.46 /MMBtu

Water Disposal

 3,900,000 Gal
0 Gal		 $ 3,500
$ 0		 11.00 %
0.00 %		 $ 0 /Gal

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 RECOVER HEAT FROM HOT WASTE WATER 2.2446 N $ 2,500 $ 10,000 0.25
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,125 MMBtu $ 10,000 $ 11.45 /MMBtu

TOTAL ENERGY

 1,125 MMBtu $ 10,000 -
02 view
details		 USE MULTIPLE SPEED MOTORS OR AFD FOR VARIABLE PUMP, BLOWER AND COMPRESSOR LOADS 2.4141 N $ 15,930 $ 14,000 1.14
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 129,000 kWh $ 14,000 $ 0.105 /kWh

TOTAL ENERGY

 1,322 MMBtu $ 14,000 -
03 view
details		 REPLACE HEAT TREATING OVEN WITH MORE EFFICIENT UNIT 2.2314 N $ 6,300 $ 10,000 0.63
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 96,000 kWh $ 10,000 $ 0.105 /kWh

TOTAL ENERGY

 984 MMBtu $ 10,000 -
04 view
details		 USE MULTIPLE SPEED MOTORS OR AFD FOR VARIABLE PUMP, BLOWER AND COMPRESSOR LOADS 2.4141 N $ 10,000 $ 8,200 1.22
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 76,300 kWh $ 8,200 $ 0.105 /kWh

TOTAL ENERGY

 782 MMBtu $ 8,200 -
05 view
details		 USE FLUE GAS HEAT TO PREHEAT BOILER FEEDWATER 2.2412 N $ 15,300 $ 8,400 1.82
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 954 MMBtu $ 8,400 $ 11.45 /MMBtu

TOTAL ENERGY

 954 MMBtu $ 8,400 -
06 view
details		 UTILIZE ENERGY-EFFICIENT BELTS AND OTHER IMPROVED MECHANISMS 2.4111 I $ 5,000 $ 6,000 0.83
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 56,500 kWh $ 6,000 $ 0.105 /kWh

TOTAL ENERGY

 579 MMBtu $ 6,000 -
07 view
details		 REPLACE CITY WATER WITH RECYCLED WATER VIA COOLING TOWER 3.4114 N $ 1,000 $ 3,500 0.29
Energy Sources Yearly Reduction Yearly Savings Unit Price

Water Disposal

 3,900,000 Gal $ 3,500 $ 0 /Gal

TOTAL WASTE

 - $ 3,500 -
08 view
details		 TURN OFF EQUIPMENT DURING BREAKS, REDUCE OPERATING TIME 2.6212 I $ 30 $ 1,900 0.02
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 17,500 kWh $ 1,900 $ 0.105 /kWh

TOTAL ENERGY

 179 MMBtu $ 1,900 -
09 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 N $ 1,331 $ 649 2.05
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 6,070 kWh $ 649 $ 0.105 /kWh

TOTAL ENERGY

 62 MMBtu $ 649 -
10 view
details		 RECYCLE AIR FOR HEATING, VENTILATION AND AIR CONDITIONING 2.7313 N $ 2,500 $ 1,200 2.08
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 140 MMBtu $ 1,200 $ 11.45 /MMBtu

TOTAL ENERGY

 140 MMBtu $ 1,200 -
11 view
details		 INSTALL ADEQUATE DRYERS ON AIR LINES TO ELIMINATE BLOWDOWN 2.4222 N $ 10,000 $ 2,800 3.57
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 26,000 kWh $ 2,800 $ 0.105 /kWh

TOTAL ENERGY

 267 MMBtu $ 2,800 -
12 view
details		 ANALYZE FLUE GAS FOR PROPER AIR/FUEL RATIO 2.1233 N $ 10,000 $ 2,700 3.70
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 310 MMBtu $ 2,700 $ 11.45 /MMBtu

TOTAL ENERGY

 310 MMBtu $ 2,700 -
13 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 N $ 970 $ 233 4.16
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 2,182 kWh $ 233 $ 0.105 /kWh

TOTAL ENERGY

 22 MMBtu $ 233 -