Industrial Assessment Centers

Assessment #GT0756

Assessment Year	2003
SIC	3325
SIC Description	Steel Foundries, Nec
NAICS	331511
NAICS Description	Iron Foundries
Principal Product	SLURRY PUMPS; IRON CASTINGS
Sales	$ 53,000,000
# of Employees	190
Plant Area (Sq.Ft.)	215,000
Annual Production	6,250 Tons
Production Hrs. Annual	8,400
Location (State)	GA
Yearly Energy Cost	$ 870,741

Current Energy Usage & Costs

Energy Sources	Yearly Usage	Yearly Cost	Unit Price
Electricity	16,526,346 kWh	$ 558,177	$ 0.034 /kWh
- Demand Charge	71,161 kW	$ 250,749	$ 3.52 /kW
- Electricity Fees	-	$ 9,778	-
Fuel Oil #2	1,177 MMBtu	$ 7,021	$ 5.97 /MMBtu
Other Gas	4,981 MMBtu	$ 45,016	$ 9.04 /MMBtu
TOTAL ENERGY	175,553 MMBtu	$ 870,741	$ 4.96 /MMBtu

Recommended Reduction in Usage & Costs

Recommended Implemented

Energy Sources	Yearly Savings	Yearly Cost	% Saved	Unit Price
Electricity	1,664,603 kWh 0 kWh	$ 82,143 $ 0	14.72 % 0.00 %	$ 0.034 /kWh
- Demand Charge	11,196 kW 0 kW	$ 76,543 $ 0	30.53 % 0.00 %	$ 3.52 /kW
- Electricity Fees	-	$ 12,647 $ 0	129.34 % 0.00 %	-
Fuel Oil #2	7,637 MMBtu 0 MMBtu	$ -47,820 $ 0	-681.10 % 0.00 %	$ 5.97 /MMBtu
Other Gas	0 MMBtu 0 MMBtu	$ 0 $ 0	0.00 % 0.00 %	$ 9.04 /MMBtu
TOTAL ENERGY	44,842 MMBtu 0 MMBtu	$ 206,777 $ 0	23.75 % 0.00 %	$ 4.96 /MMBtu

Recommendations

AR #

Description

ARC Code

Status

Cost

Savings

Payback
(Years)

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details

ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES

2.4236

$ 1,100

$ 510

2.16

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Electricity	14,443 kWh	$ 510	$ 0.034 /kWh
TOTAL ENERGY	148 MMBtu	$ 510	-

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details

COVER OPEN TANKS

2.2514

$ 3,000

$ 18,300

0.16

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Electricity	515,200 kWh	$ 18,300	$ 0.034 /kWh
TOTAL ENERGY	5,281 MMBtu	$ 18,300	-

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details

ENHANCE SENSITIVITY OF TEMPERATURE CONTROL AND CUTOFF

2.2223

$ 5,610

$ 22,800

0.25

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Natural Gas	5,616 MMBtu	$ 22,800	$ 0.00 /MMBtu
TOTAL ENERGY	5,616 MMBtu	$ 22,800	-

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details

USE INSULATION IN FURNACES TO FACILITATE HEATING / COOLING

2.1121

$ 1,620

$ 2,950

0.55

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Natural Gas	727 MMBtu	$ 2,950	$ 0.00 /MMBtu
TOTAL ENERGY	727 MMBtu	$ 2,950	-

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details

USE CLOSED CYCLE PROCESS TO MINIMIZE WASTE WATER PRODUCTION

3.4111

$ 35,955

$ 10,000

3.60

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Water Consumption	-	$ 10,000	-
TOTAL PRODUCTON	-	$ 10,000	-

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details

METER RECYCLED WATER (TO REDUCE SEWER CHARGES)

3.4116

$ 1,850

$ 2,680

0.69

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Water Disposal	0 Gal	$ 2,680	$ 0 /Gal
TOTAL WASTE	-	$ 2,680	-

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details

RESCHEDULE AND REARRANGE MULTIPLE-SOURCE HEATING SYSTEMS

2.7291

$ 1,500

$ 56,040

0.03

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Natural Gas	13,800 MMBtu	$ 56,040	$ 0.00 /MMBtu
TOTAL ENERGY	13,800 MMBtu	$ 56,040	-

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details

REPLACE ELECTRIC MOTOR WITH FOSSIL FUEL ENGINE

2.4134

$ 200,000

$ 89,400

2.24

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Electricity	895,860 kWh	$ 54,830	$ 0.034 /kWh
- Demand Charge	11,196 kW	$ 76,543	$ 3.52 /kW
- Electricity Fees	-	$ 5,847	-
Fuel Oil #2	7,637 MMBtu	$ -47,820	$ 5.97 /MMBtu
TOTAL ENERGY	16,820 MMBtu	$ 89,400	-

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details

MAKE A PRACTICE OF TURNING OFF LIGHTS WHEN NOT NEEDED

2.7124

$ 0

$ 784

0.00

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Electricity	22,080 kWh	$ 784	$ 0.034 /kWh
TOTAL ENERGY	226 MMBtu	$ 784	-

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details

UTILIZE DAYLIGHT WHENEVER POSSIBLE IN LIEU OF ARTIFICIAL LIGHT

2.7121

$ 10,980

$ 5,098

2.15

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Electricity	143,520 kWh	$ 5,098	$ 0.034 /kWh
TOTAL ENERGY	1,471 MMBtu	$ 5,098	-

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details

CHANGE RATE SCHEDULES OR OTHER CHANGES IN UTILITY SERVICE

2.8114

$ 0

$ 3,820

0.00

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
- Electricity Fees	-	$ 3,820	-
TOTAL ENERGY	0 MMBtu	$ 3,820	-

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details

INSULATE BARE EQUIPMENT

2.2511

$ 1,730

$ 1,474

1.17

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Other Energy	0 MMBtu	$ 1,474	$ 0.00 /MMBtu
TOTAL ENERGY	0 MMBtu	$ 1,474	-

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details

TURN OFF EQUIPMENT WHEN NOT IN USE

2.6218

$ 0

$ 556

0.00

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Electricity	15,700 kWh	$ 556	$ 0.034 /kWh
TOTAL ENERGY	161 MMBtu	$ 556	-

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details

COMBINE UTILITY METERS

2.8112

$ 0

$ 2,980

0.00

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
- Electricity Fees	-	$ 2,980	-
TOTAL ENERGY	0 MMBtu	$ 2,980	-

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details

UTILIZE ENERGY-EFFICIENT BELTS AND OTHER IMPROVED MECHANISMS

2.4111

$ 0

$ 2,065

0.00

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Electricity	57,800 kWh	$ 2,065	$ 0.034 /kWh
TOTAL ENERGY	592 MMBtu	$ 2,065	-