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

Industrial Assessment Centers

Assessment #IC0087


Assessment Year 2004
SIC 2899
SIC Description Chemical Preparations, Nec
NAICS 325510
NAICS Description Paint and Coating Manufacturing
Principal Product photo, pharmaceutical and good grade gelatine
Sales $ 35,000,000
# of Employees 72
Plant Area (Sq.Ft.) 200,000
Annual Production 8,200,000 Pounds
Production Hrs. Annual 8,592
Location (State) IL
Yearly Energy Cost $ 2,065,777

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 10,483,713 kWh $ 344,743 $ 0.033 /kWh

- Demand Charge

 17,426 kW $ 144,617 $ 8.30 /kW

- Electricity Fees

 - $ 174,683 -

Natural Gas

 244,220 MMBtu $ 1,401,734 $ 5.74 /MMBtu

TOTAL ENERGY

 351,678 MMBtu $ 2,065,777 $ 5.87 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 2,318,392 kWh
-116,200 kWh		 $ 54,111
$ -5,085		 15.70 %
-1.48 %		 $ 0.033 /kWh

- Demand Charge

 3,380 kW
-160 kW		 $ 28,061
$ -1,324		 19.40 %
-0.92 %		 $ 8.30 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 109,632 MMBtu
53,538 MMBtu		 $ 638,775
$ 307,313		 45.57 %
21.92 %		 $ 5.74 /MMBtu

TOTAL ENERGY

 133,396 MMBtu
52,347 MMBtu		 $ 720,947
$ 300,904		 34.90 %
14.57 %		 $ 5.87 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 FLASH CONDENSATE TO PRODUCE LOWER PRESSURE STEAM 2.2127 N $ 2,078 $ 210,887 0.01
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 32,427 MMBtu $ 195,613 $ 5.74 /MMBtu

TOTAL ENERGY

 32,427 MMBtu $ 195,613 -

Water Consumption

 - $ 15,274 -

TOTAL PRODUCTON

 - $ 15,274 -
02 view
details		 SUBSTITUTE HOT PROCESS FLUIDS FOR STEAM 2.2191 N $ 18,578 $ 135,849 0.14
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 23,667 MMBtu $ 135,849 $ 5.74 /MMBtu

TOTAL ENERGY

 23,667 MMBtu $ 135,849 -
03 view
details		 USE WASTE HEAT FROM HOT FLUE GASES TO PREHEAT INCOMING FLUIDS 2.2427 I $ 4,311 $ 216,557 0.02
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 -45,402 kWh $ -1,998 $ 0.033 /kWh

- Demand Charge

 -63 kW $ -523 $ 8.30 /kW

Natural Gas

 37,528 MMBtu $ 215,411 $ 5.74 /MMBtu

TOTAL ENERGY

 37,063 MMBtu $ 212,890 -

Ancillary Material Cost

 - $ 3,667 -

TOTAL PRODUCTON

 - $ 3,667 -
04 view
details		 USE FLUE GAS HEAT TO PREHEAT BOILER FEEDWATER 2.2412 I $ 6,900 $ 43,578 0.16
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 7,591 MMBtu $ 43,578 $ 5.74 /MMBtu

TOTAL ENERGY

 7,591 MMBtu $ 43,578 -
05 view
details		 USE STEAM PRESSURE REDUCTION TO GENERATE POWER 2.3321 N $ 1,560 $ 53,985 0.03
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 1,997,265 kWh $ 39,949 $ 0.033 /kWh

- Demand Charge

 2,736 kW $ 22,709 $ 8.30 /kW

TOTAL ENERGY

 20,472 MMBtu $ 62,658 -

Personnel Changes

 - $ -8,673 -

TOTAL PRODUCTON

 - $ -8,673 -
06 view
details		 USE WASTE HEAT FROM HOT FLUE GASES TO PREHEAT COMBUSTION AIR 2.2411 I $ 8,465 $ 14,571 0.58
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 -96,947 kWh $ -4,266 $ 0.033 /kWh

- Demand Charge

 -133 kW $ -1,104 $ 8.30 /kW

Natural Gas

 3,474 MMBtu $ 19,941 $ 5.74 /MMBtu

TOTAL ENERGY

 2,480 MMBtu $ 14,571 -
07 view
details		 INSULATE BARE EQUIPMENT 2.2511 I $ 56,925 $ 28,383 2.01
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 4,945 MMBtu $ 28,383 $ 5.74 /MMBtu

TOTAL ENERGY

 4,945 MMBtu $ 28,383 -
08 view
details		 UTILIZE CONTROLS TO OPERATE EQUIPMENT ONLY WHEN NEEDED 2.6231 N $ 609,500 $ 4,114 148.15
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 51,822 kWh $ 2,280 $ 0.033 /kWh

- Demand Charge

 221 kW $ 1,834 $ 8.30 /kW

TOTAL ENERGY

 531 MMBtu $ 4,114 -
09 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 N $ 104,650 $ 14,613 7.16
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 262,859 kWh $ 11,566 $ 0.033 /kWh

- Demand Charge

 367 kW $ 3,047 $ 8.30 /kW

TOTAL ENERGY

 2,694 MMBtu $ 14,613 -
10 view
details		 USE MOST EFFICIENT TYPE OF ELECTRIC MOTORS 2.4133 I $ 79,350 $ 1,168 67.94
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 21,024 kWh $ 924 $ 0.033 /kWh

- Demand Charge

 29 kW $ 244 $ 8.30 /kW

TOTAL ENERGY

 215 MMBtu $ 1,168 -
11 view
details		 LOWER LIGHT FIXTURES IN HIGH CEILING AREAS 2.7141 N $ 332,143 $ 8,624 38.51
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 122,646 kWh $ 5,401 $ 0.033 /kWh

- Demand Charge

 216 kW $ 1,795 $ 8.30 /kW

TOTAL ENERGY

 1,257 MMBtu $ 7,196 -

Administrative Changes

 - $ 859 -

Ancillary Material Cost

 - $ 569 -

TOTAL PRODUCTON

 - $ 1,428 -
12 view
details		 LOWER LIGHT FIXTURES IN HIGH CEILING AREAS 2.7141 I $ 174,800 $ 592 295.27
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 5,125 kWh $ 255 $ 0.033 /kWh

- Demand Charge

 7 kW $ 59 $ 8.30 /kW

TOTAL ENERGY

 53 MMBtu $ 314 -

Administrative Changes

 - $ 114 -

Ancillary Material Cost

 - $ 164 -

TOTAL PRODUCTON

 - $ 278 -