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

Industrial Assessment Centers

Assessment #IA0227


Assessment Year 1999
SIC 3325
SIC Description Steel Foundries, Nec
NAICS
NAICS Description
Principal Product steel castings
Sales $ 50,000,000
# of Employees 425
Plant Area (Sq.Ft.) 150,000
Annual Production 11,700 Tons
Production Hrs. Annual 4,420
Location (State) IA
Yearly Energy Cost $ 1,184,046

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 30,156,507 kWh $ 721,763 $ 0.024 /kWh

- Demand Charge

 39,852 kW $ 38,271 $ 0.96 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 151,180 MMBtu $ 424,012 $ 2.80 /MMBtu

TOTAL ENERGY

 460,284 MMBtu $ 1,184,046 $ 2.57 /MMBtu

Water Disposal

 35,240,172 Gal $ 73,320 $ 0 /Gal

Other Liquid (non-haz)

 2,321,785 Gal $ 30,369 $ 0 /Gal

Recommended Reduction in Usage & Costs

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

Electricity

 3,367,820 kWh
0 kWh		 $ 933,146
$ 0		 129.29 %
0.00 %		 $ 0.024 /kWh

- Demand Charge

 7,332 kW
0 kW		 $ 83,530
$ 0		 218.26 %
0.00 %		 $ 0.96 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 0 MMBtu
0 MMBtu		 $ 0
$ 0		 0.00 %
0.00 %		 $ 2.80 /MMBtu

TOTAL ENERGY

 34,520 MMBtu
0 MMBtu		 $ 1,016,676
$ 0		 85.86 %
0.00 %		 $ 2.57 /MMBtu

Water Disposal

 2,761,923 Gal
0 Gal		 $ 8,818
$ 0		 12.03 %
0.00 %		 $ 0 /Gal

Other Liquid (non-haz)

 464,358 Gal
0 Gal		 $ 6,074
$ 0		 20.00 %
0.00 %		 $ 0 /Gal

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 K $ 1,863 $ 825,660 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 2,751,759 kWh $ 762,443 $ 0.024 /kWh

- Demand Charge

 5,549 kW $ 63,217 $ 0.96 /kW

TOTAL ENERGY

 28,206 MMBtu $ 825,660 -
02 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 K $ 2,000 $ 66,200 0.03
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 214,244 kWh $ 59,364 $ 0.024 /kWh

- Demand Charge

 600 kW $ 6,836 $ 0.96 /kW

TOTAL ENERGY

 2,196 MMBtu $ 66,200 -
03 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 K $ 150 $ 25,100 0.01
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 81,184 kWh $ 22,491 $ 0.024 /kWh

- Demand Charge

 229 kW $ 2,609 $ 0.96 /kW

TOTAL ENERGY

 832 MMBtu $ 25,100 -
04 view
details		 USE MOST EFFICIENT TYPE OF ELECTRIC MOTORS 2.4133 K $ 0 $ 72,026 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 233,001 kWh $ 64,530 $ 0.024 /kWh

- Demand Charge

 658 kW $ 7,496 $ 0.96 /kW

TOTAL ENERGY

 2,388 MMBtu $ 72,026 -
05 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 K $ 0 $ 16,875 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 53,927 kWh $ 14,961 $ 0.024 /kWh

- Demand Charge

 168 kW $ 1,914 $ 0.96 /kW

TOTAL ENERGY

 553 MMBtu $ 16,875 -
06 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 K $ 2,113 $ 5,254 0.40
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 13,775 kWh $ 3,796 $ 0.024 /kWh

- Demand Charge

 128 kW $ 1,458 $ 0.96 /kW

TOTAL ENERGY

 141 MMBtu $ 5,254 -
07 view
details		 INSTALL OCCUPANCY SENSORS 2.7135 K $ 1,330 $ 5,561 0.24
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 19,930 kWh $ 5,561 $ 0.024 /kWh

TOTAL ENERGY

 204 MMBtu $ 5,561 -
08 view
details		 MODIFY PROCESS TO REDUCE MATERIAL USE/COST 4.1310 K $ 3,038 $ 6,074 0.50
Energy Sources Yearly Reduction Yearly Savings Unit Price

Other Liquid (non-haz)

 464,358 Gal $ 6,074 $ 0 /Gal

TOTAL WASTE

 - $ 6,074 -
09 view
details		 MAINTAIN MACHINES TO REDUCE LEAKS 3.7311 K $ 3,906 $ 5,867 0.67
Energy Sources Yearly Reduction Yearly Savings Unit Price

Water Disposal

 1,077,120 Gal $ 5,867 $ 0 /Gal

TOTAL WASTE

 - $ 5,867 -
10 view
details		 MAINTAIN MACHINES TO REDUCE LEAKS 3.7311 K $ 213 $ 2,951 0.07
Energy Sources Yearly Reduction Yearly Savings Unit Price

Water Disposal

 1,684,803 Gal $ 2,951 $ 0 /Gal

TOTAL WASTE

 - $ 2,951 -
11 view
details		 REPLACE EXISTING EQUIPMENT WITH MORE SUITABLE SUBSTITUTES 4.6520 K $ 166,000 $ 150,880 1.10
Energy Sources Yearly Reduction Yearly Savings Unit Price

Personnel Changes

 - $ 150,880 -

TOTAL PRODUCTON

 - $ 150,880 -
12 view
details		 INSTALL EQUIPMENT TO MOVE PRODUCT 4.4450 K $ 133,000 $ 150,880 0.88
Energy Sources Yearly Reduction Yearly Savings Unit Price

Personnel Changes

 - $ 150,880 -

TOTAL PRODUCTON

 - $ 150,880 -
13 view
details		 REPLACE EXISTING EQUIPMENT WITH MORE SUITABLE SUBSTITUTES 4.6520 K $ 136,000 $ 150,880 0.90
Energy Sources Yearly Reduction Yearly Savings Unit Price

Personnel Changes

 - $ 150,880 -

TOTAL PRODUCTON

 - $ 150,880 -
14 view
details		 REPLACE EXISTING EQUIPMENT WITH MORE SUITABLE SUBSTITUTES 4.6520 K $ 154,000 $ 150,880 1.02
Energy Sources Yearly Reduction Yearly Savings Unit Price

Personnel Changes

 - $ 150,880 -

TOTAL PRODUCTON

 - $ 150,880 -
15 view
details		 REPLACE EXISTING EQUIPMENT WITH MORE SUITABLE SUBSTITUTES 4.6520 K $ 146,000 $ 75,440 1.94
Energy Sources Yearly Reduction Yearly Savings Unit Price

Personnel Changes

 - $ 75,440 -

TOTAL PRODUCTON

 - $ 75,440 -
16 view
details		 REPLACE EXISTING EQUIPMENT WITH MORE SUITABLE SUBSTITUTES 4.6520 K $ 150,000 $ 75,440 1.99
Energy Sources Yearly Reduction Yearly Savings Unit Price

Personnel Changes

 - $ 75,440 -

TOTAL PRODUCTON

 - $ 75,440 -