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

Industrial Technologies Program

Industrial Assessment Centers

Assessment #LE0271


Assessment Year 2008
SIC 3357
SIC Description Nonferrous Wiredrawing & Insulating
NAICS 331319
NAICS Description Other Aluminum Rolling and Drawing
Principal Product Aluminum Wire, Cable
Sales $ 850,000,000
# of Employees 212
Plant Area (Sq.Ft.) 400,000
Annual Production 106,000,000 Pounds
Production Hrs. Annual 8,568
Location (State) PA
Yearly Energy Cost $ 1,607,285

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 18,788,000 kWh $ 1,003,535 $ 0.053 /kWh

- Demand Charge

 35,575 kW $ 225,637 $ 6.34 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 40,725 MMBtu $ 378,113 $ 9.28 /MMBtu

TOTAL ENERGY

 233,302 MMBtu $ 1,607,285 $ 6.89 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 2,686,552 kWh
1,554,782 kWh		 $ 142,387
$ 82,404		 14.19 %
8.21 %		 $ 0.053 /kWh

- Demand Charge

 2,311 kW
1,140 kW		 $ 14,648
$ 7,225		 6.49 %
3.20 %		 $ 6.34 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 4,169 MMBtu
0 MMBtu		 $ 38,683
$ 0		 10.23 %
0.00 %		 $ 9.28 /MMBtu

TOTAL ENERGY

 33,604 MMBtu
15,937 MMBtu		 $ 213,322
$ 89,629		 13.27 %
5.58 %		 $ 6.89 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 REPLACE DC EQUIPMENT WITH AC EQUIPMENT 2.3311 I $ 45,000 $ 94,198 0.48
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 1,304,476 kWh $ 69,138 $ 0.053 /kWh

- Demand Charge

 666 kW $ 4,220 $ 6.34 /kW

TOTAL ENERGY

 13,371 MMBtu $ 73,358 -

Administrative Changes

 - $ 10,000 -

Ancillary Material Cost

 - $ 10,840 -

TOTAL PRODUCTON

 - $ 20,840 -
02 view
details		 INSTALL TIMERS AND/OR THERMOSTATS 2.7261 N $ 875 $ 35,042 0.02
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 439,518 kWh $ 23,294 $ 0.053 /kWh

Natural Gas

 1,266 MMBtu $ 11,748 $ 9.28 /MMBtu

TOTAL ENERGY

 5,771 MMBtu $ 35,042 -
03 view
details		 USE ADJUSTABLE FREQUENCY DRIVE TO REPLACE MOTOR-GENERATOR SET 2.4142 N $ 40,000 $ 27,263 1.47
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 420,382 kWh $ 22,280 $ 0.053 /kWh

- Demand Charge

 786 kW $ 4,983 $ 6.34 /kW

TOTAL ENERGY

 4,309 MMBtu $ 27,263 -
04 view
details		 USE RADIANT HEATER FOR SPOT HEATING 2.7231 N $ 3,900 $ 17,604 0.22
Energy Sources Yearly Reduction Yearly Savings Unit Price

LPG

 1,897 MMBtu $ 17,604 $ 0.00 /MMBtu

TOTAL ENERGY

 1,897 MMBtu $ 17,604 -
05 view
details		 PREHEAT COMBUSTION AIR WITH WASTE HEAT 2.2442 N $ 30,000 $ 14,909 2.01
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,607 MMBtu $ 14,909 $ 9.28 /MMBtu

TOTAL ENERGY

 1,607 MMBtu $ 14,909 -
06 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 3,000 $ 13,337 0.22
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 214,323 kWh $ 11,359 $ 0.053 /kWh

- Demand Charge

 312 kW $ 1,978 $ 6.34 /kW

TOTAL ENERGY

 2,197 MMBtu $ 13,337 -
07 view
details		 RECOVER HEAT FROM AIR COMPRESSOR 2.2434 N $ 1,000 $ 6,931 0.14
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 747 MMBtu $ 6,931 $ 9.28 /MMBtu

TOTAL ENERGY

 747 MMBtu $ 6,931 -
08 view
details		 REPAIR FAULTY INSULATION IN FURNACES, BOILERS, ETC 2.1131 N $ 7,278 $ 5,095 1.43
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 549 MMBtu $ 5,095 $ 9.28 /MMBtu

TOTAL ENERGY

 549 MMBtu $ 5,095 -
09 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 I $ 1,000 $ 2,934 0.34
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 35,983 kWh $ 1,907 $ 0.053 /kWh

- Demand Charge

 162 kW $ 1,027 $ 6.34 /kW

TOTAL ENERGY

 369 MMBtu $ 2,934 -
10 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 N $ 150 $ 1,865 0.08
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 29,926 kWh $ 1,586 $ 0.053 /kWh

- Demand Charge

 44 kW $ 279 $ 6.34 /kW

TOTAL ENERGY

 307 MMBtu $ 1,865 -
11 view
details		 UTILIZE ENERGY-EFFICIENT BELTS AND OTHER IMPROVED MECHANISMS 2.4111 N $ 500 $ 804 0.62
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 13,265 kWh $ 703 $ 0.053 /kWh

- Demand Charge

 16 kW $ 101 $ 6.34 /kW

TOTAL ENERGY

 136 MMBtu $ 804 -
12 view
details		 REDUCE ILLUMINATION TO MINIMUM NECESSARY LEVELS 2.7111 N $ 255 $ 704 0.36
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 12,012 kWh $ 637 $ 0.053 /kWh

- Demand Charge

 9 kW $ 57 $ 6.34 /kW

TOTAL ENERGY

 123 MMBtu $ 694 -

One-time Revenue or Avoided Cost

 - $ 10 -

TOTAL PRODUCTON

 - $ 10 -
13 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 N $ 54,562 $ 13,736 3.97
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 216,667 kWh $ 11,483 $ 0.053 /kWh

- Demand Charge

 316 kW $ 2,003 $ 6.34 /kW

TOTAL ENERGY

 2,221 MMBtu $ 13,486 -

One-time Revenue or Avoided Cost

 - $ 250 -

TOTAL PRODUCTON

 - $ 250 -