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

Industrial Assessment Centers

Assessment #KU0163


Assessment Year 1985
SIC 3366
SIC Description Copper Foundries
NAICS
NAICS Description
Principal Product METAL CASTINGS
Sales $ 4,500,000
# of Employees 70
Plant Area (Sq.Ft.) 0
Annual Production 800,000 Pounds
Production Hrs. Annual 2,100
Location (State) KS
Yearly Energy Cost $ 174,471

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 2,625,147 kWh $ 145,257 $ 0.055 /kWh

- Electricity Fees

 - $ 0 -

Natural Gas

 6,207 MMBtu $ 29,214 $ 4.71 /MMBtu

TOTAL ENERGY

 33,115 MMBtu $ 174,471 $ 5.27 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 188,161 kWh
84,702 kWh		 $ 10,414
$ 4,688		 7.17 %
3.23 %		 $ 0.055 /kWh

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 1,889 MMBtu
1,008 MMBtu		 $ 9,646
$ 4,749		 33.02 %
16.26 %		 $ 4.71 /MMBtu

TOTAL ENERGY

 3,817 MMBtu
1,876 MMBtu		 $ 20,060
$ 9,437		 11.50 %
5.41 %		 $ 5.27 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 USE HOT PROCESS FLUIDS TO PREHEAT INCOMING PROCESS FLUIDS 2.2444 N $ 10,700 $ 12,428 0.86
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 250 MMBtu $ 1,178 $ 4.71 /MMBtu

TOTAL ENERGY

 250 MMBtu $ 1,178 -

Administrative Changes

 - $ 11,250 -

TOTAL PRODUCTON

 - $ 11,250 -
02 view
details		 USE OR REPLACE WITH ENERGY EFFICIENT SUBSTITUTES 2.4322 I $ 500 $ 2,439 0.21
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 624 MMBtu $ 2,939 $ 4.71 /MMBtu

TOTAL ENERGY

 624 MMBtu $ 2,939 -

Administrative Changes

 - $ -500 -

TOTAL PRODUCTON

 - $ -500 -
03 view
details		 RE-SIZE CHARGING OPENINGS OR ADD A MOVABLE DOOR ON EQUIPMENT 2.1122 I $ 400 $ 461 0.87
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 9,086 kWh $ 503 $ 0.055 /kWh

Natural Gas

 -9 MMBtu $ -42 $ 4.71 /MMBtu

TOTAL ENERGY

 84 MMBtu $ 461 -
04 view
details		 INSULATE BARE EQUIPMENT 2.2511 I $ 60 $ 499 0.12
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 106 MMBtu $ 499 $ 4.71 /MMBtu

TOTAL ENERGY

 106 MMBtu $ 499 -
05 view
details		 TURN OFF EQUIPMENT DURING BREAKS, REDUCE OPERATING TIME 2.6212 N $ 50 $ 1,087 0.05
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 19,637 kWh $ 1,087 $ 0.055 /kWh

TOTAL ENERGY

 201 MMBtu $ 1,087 -
06 view
details		 TURN OFF EQUIPMENT DURING BREAKS, REDUCE OPERATING TIME 2.6212 I $ 0 $ 979 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 24,912 kWh $ 1,379 $ 0.055 /kWh

TOTAL ENERGY

 255 MMBtu $ 1,379 -

Administrative Changes

 - $ -400 -

TOTAL PRODUCTON

 - $ -400 -
07 view
details		 RE-USE OR RECYCLE HOT OR COLD PROCESS EXHAUST AIR 2.2443 N $ 4,200 $ 2,124 1.98
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 451 MMBtu $ 2,124 $ 4.71 /MMBtu

TOTAL ENERGY

 451 MMBtu $ 2,124 -
08 view
details		 RE-USE OR RECYCLE HOT OR COLD PROCESS EXHAUST AIR 2.2443 N $ 750 $ 400 1.88
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 85 MMBtu $ 400 $ 4.71 /MMBtu

TOTAL ENERGY

 85 MMBtu $ 400 -
09 view
details		 MINIMIZE USE OF OUTSIDE MAKE-UP AIR FOR VENTILATION EXCEPT WHEN USED FOR ECONOMIZER CYCLE 2.7312 I $ 140 $ 462 0.30
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 98 MMBtu $ 462 $ 4.71 /MMBtu

TOTAL ENERGY

 98 MMBtu $ 462 -
10 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 N $ 50 $ 1,233 0.04
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 22,274 kWh $ 1,233 $ 0.055 /kWh

TOTAL ENERGY

 228 MMBtu $ 1,233 -
11 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 180 $ 130 1.38
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 2,345 kWh $ 130 $ 0.055 /kWh

TOTAL ENERGY

 24 MMBtu $ 130 -
12 view
details		 TURN OFF EQUIPMENT DURING BREAKS, REDUCE OPERATING TIME 2.6212 I $ 455 $ 357 1.27
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 6,448 kWh $ 357 $ 0.055 /kWh

TOTAL ENERGY

 66 MMBtu $ 357 -
13 view
details		 TURN OFF EQUIPMENT DURING BREAKS, REDUCE OPERATING TIME 2.6212 I $ 175 $ 324 0.54
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 5,862 kWh $ 324 $ 0.055 /kWh

TOTAL ENERGY

 60 MMBtu $ 324 -
14 view
details		 RECOVER WASTE HEAT FROM EQUIPMENT 2.2437 N $ 500 $ 1,054 0.47
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 65 MMBtu $ 1,054 $ 4.71 /MMBtu

TOTAL ENERGY

 65 MMBtu $ 1,054 -
15 view
details		 IMPROVE LUBRICATION PRACTICES 2.4312 N $ 1,016 $ 1,119 0.91
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 20,223 kWh $ 1,119 $ 0.055 /kWh

TOTAL ENERGY

 207 MMBtu $ 1,119 -
16 view
details		 INSTALL TIMERS AND/OR THERMOSTATS 2.7261 I $ 1,000 $ 2,273 0.44
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 36,049 kWh $ 1,995 $ 0.055 /kWh

Natural Gas

 59 MMBtu $ 278 $ 4.71 /MMBtu

TOTAL ENERGY

 429 MMBtu $ 2,273 -
17 view
details		 INSTALL AUTOMATIC STACK DAMPER 2.1123 I $ 900 $ 363 2.48
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 77 MMBtu $ 363 $ 4.71 /MMBtu

TOTAL ENERGY

 77 MMBtu $ 363 -
18 view
details		 SHUT OFF PILOTS IN STANDBY EQUIPMENT 2.6214 I $ 0 $ 160 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 53 MMBtu $ 250 $ 4.71 /MMBtu

TOTAL ENERGY

 53 MMBtu $ 250 -

Administrative Changes

 - $ -90 -

TOTAL PRODUCTON

 - $ -90 -
19 view
details		 ANALYZE FLUE GAS FOR PROPER AIR/FUEL RATIO 2.1233 N $ 0 $ 11 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 30 MMBtu $ 141 $ 4.71 /MMBtu

TOTAL ENERGY

 30 MMBtu $ 141 -

Administrative Changes

 - $ -130 -

TOTAL PRODUCTON

 - $ -130 -
20 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 N $ 2,874 $ 2,287 1.26
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 41,325 kWh $ 2,287 $ 0.055 /kWh

TOTAL ENERGY

 424 MMBtu $ 2,287 -