U.S. Department of Energy - Energy Efficiency and Renewable Energy

Industrial Technologies Program

Industrial Assessment Centers

Assessment #IC0084


Assessment Year 2004
SIC 3315
SIC Description Steel Wire And Related Products
NAICS 331222
NAICS Description Steel Wire Drawing
Principal Product Drawn Wire
Sales $ 75,000,000
# of Employees 118
Plant Area (Sq.Ft.) 204,500
Annual Production 175,000 Tons
Production Hrs. Annual 7,248
Location (State) IN
Yearly Energy Cost $ 2,086,483

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 27,900,000 kWh $ 1,255,500 $ 0.045 /kWh

- Demand Charge

 60,348 kW $ 407,176 $ 6.75 /kW

- Electricity Fees

 - $ -183,017 -

Natural Gas

 98,353 MMBtu $ 606,824 $ 6.17 /MMBtu

TOTAL ENERGY

 384,328 MMBtu $ 2,086,483 $ 5.43 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 2,485,307 kWh
2,286,532 kWh		 $ 93,983
$ 86,434		 7.49 %
6.88 %		 $ 0.045 /kWh

- Demand Charge

 4,123 kW
3,830 kW		 $ 25,784
$ 23,945		 6.33 %
5.88 %		 $ 6.75 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 30,425 MMBtu
11,510 MMBtu		 $ 187,723
$ 71,017		 30.94 %
11.70 %		 $ 6.17 /MMBtu

TOTAL ENERGY

 55,899 MMBtu
34,947 MMBtu		 $ 307,490
$ 181,396		 14.74 %
8.69 %		 $ 5.43 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 INCREASE AMOUNT OF CONDENSATE RETURNED 2.2121 N $ 13,907 $ 144,862 0.10
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 15,461 MMBtu $ 95,394 $ 6.17 /MMBtu

TOTAL ENERGY

 15,461 MMBtu $ 95,394 -

Water Consumption

 - $ 49,468 -

TOTAL PRODUCTON

 - $ 49,468 -
02 view
details		 ELIMINATE LEAKS IN COMBUSTIBLE GAS LINES 2.1134 I $ 0 $ 105 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 17 MMBtu $ 105 $ 6.17 /MMBtu

TOTAL ENERGY

 17 MMBtu $ 105 -
03 view
details		 INSULATE STEAM / HOT WATER LINES 2.2131 I $ 400 $ 1,035 0.39
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 168 MMBtu $ 1,035 $ 6.17 /MMBtu

TOTAL ENERGY

 168 MMBtu $ 1,035 -
04 view
details		 REPAIR LEAKS IN LINES AND VALVES 2.2133 I $ 585 $ 4,809 0.12
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 779 MMBtu $ 4,809 $ 6.17 /MMBtu

TOTAL ENERGY

 779 MMBtu $ 4,809 -
05 view
details		 ANALYZE FLUE GAS FOR PROPER AIR/FUEL RATIO 2.1233 N $ 4,021 $ 18,612 0.22
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 3,454 MMBtu $ 21,312 $ 6.17 /MMBtu

TOTAL ENERGY

 3,454 MMBtu $ 21,312 -

Personnel Changes

 - $ -2,700 -

TOTAL PRODUCTON

 - $ -2,700 -
06 view
details		 DIRECT WARMEST AIR TO COMBUSTION INTAKE 2.1213 I $ 582,998 $ 943 618.24
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 -83,220 kWh $ -3,618 $ 0.045 /kWh

- Demand Charge

 -120 kW $ -744 $ 6.75 /kW

Natural Gas

 860 MMBtu $ 5,305 $ 6.17 /MMBtu

TOTAL ENERGY

 7 MMBtu $ 943 -
07 view
details		 ELIMINATE LEAKS IN WATER LINES AND VALVES 3.4154 N $ 430,000 $ 2,024 212.45
Energy Sources Yearly Reduction Yearly Savings Unit Price

Water Disposal

 374,844 Gal $ 2,024 $ 0 /Gal

TOTAL WASTE

 - $ 2,024 -
08 view
details		 USE WASTE HEAT FROM HOT FLUE GASES TO GENERATE STEAM 2.2422 I $ 200 $ 48,922 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 -231,848 kWh $ -8,810 $ 0.045 /kWh

- Demand Charge

 -325 kW $ -2,031 $ 6.75 /kW

Natural Gas

 9,686 MMBtu $ 59,763 $ 6.17 /MMBtu

TOTAL ENERGY

 7,310 MMBtu $ 48,922 -
09 view
details		 USE MOST EFFICIENT TYPE OF ELECTRIC MOTORS 2.4133 I $ 513 $ 124,469 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 2,577,273 kWh $ 97,937 $ 0.045 /kWh

- Demand Charge

 4,245 kW $ 26,532 $ 6.75 /kW

TOTAL ENERGY

 26,417 MMBtu $ 124,469 -
10 view
details		 USE MULTIPLE SPEED MOTORS OR AFD FOR VARIABLE PUMP, BLOWER AND COMPRESSOR LOADS 2.4141 I $ 5,100 $ 794 6.42
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 17,056 kWh $ 648 $ 0.045 /kWh

- Demand Charge

 23 kW $ 146 $ 6.75 /kW

TOTAL ENERGY

 175 MMBtu $ 794 -
11 view
details		 INSTALL ADEQUATE DRYERS ON AIR LINES TO ELIMINATE BLOWDOWN 2.4222 I $ 0 $ 122 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 3,202 kWh $ 122 $ 0.045 /kWh

TOTAL ENERGY

 33 MMBtu $ 122 -
12 view
details		 ESTABLISH BURNER MAINTENANCE SCHEDULE FOR BOILERS 2.1231 N $ 1,854 $ 156 11.88
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 3,336 kWh $ 127 $ 0.045 /kWh

- Demand Charge

 5 kW $ 29 $ 6.75 /kW

TOTAL ENERGY

 34 MMBtu $ 156 -
13 view
details		 SUBSTITUTE COMPRESSED AIR COOLING WITH WATER OR AIR COOLING 2.4237 I $ 240 $ 197 1.22
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 4,069 kWh $ 155 $ 0.045 /kWh

- Demand Charge

 7 kW $ 42 $ 6.75 /kW

TOTAL ENERGY

 42 MMBtu $ 197 -
14 view
details		 REDUCE ILLUMINATION TO MINIMUM NECESSARY LEVELS 2.7111 N $ 96,551 $ 3,645 26.49
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 108,417 kWh $ 4,121 $ 0.045 /kWh

- Demand Charge

 177 kW $ 1,107 $ 6.75 /kW

TOTAL ENERGY

 1,111 MMBtu $ 5,228 -

Administrative Changes

 - $ -1,583 -

TOTAL PRODUCTON

 - $ -1,583 -
15 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 N $ 13,349 $ 2,601 5.13
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 38,465 kWh $ 1,458 $ 0.045 /kWh

- Demand Charge

 84 kW $ 530 $ 6.75 /kW

TOTAL ENERGY

 394 MMBtu $ 1,988 -

Personnel Changes

 - $ 105 -

Administrative Changes

 - $ 508 -

TOTAL PRODUCTON

 - $ 613 -
16 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 N $ 2,376 $ 1,775 1.34
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 6,925 kWh $ 263 $ 0.045 /kWh

- Demand Charge

 10 kW $ 59 $ 6.75 /kW

TOTAL ENERGY

 71 MMBtu $ 322 -

Personnel Changes

 - $ 416 -

Administrative Changes

 - $ 1,037 -

TOTAL PRODUCTON

 - $ 1,453 -
17 view
details		 INSTALL TIMERS ON LIGHT SWITCHES IN LITTLE USED AREAS 2.7132 N $ 5,190 $ 1,694 3.06
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 41,632 kWh $ 1,580 $ 0.045 /kWh

- Demand Charge

 17 kW $ 114 $ 6.75 /kW

TOTAL ENERGY

 427 MMBtu $ 1,694 -