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

Industrial Technologies Program

Industrial Assessment Centers

Assessment #MA0488


Assessment Year 2001
SIC 2621
SIC Description Paper Mills
NAICS
NAICS Description
Principal Product Paper
Sales $ 60,000,000
# of Employees 225
Plant Area (Sq.Ft.) 200,000
Annual Production 40,000 Tons
Production Hrs. Annual 8,600
Location (State) VT
Yearly Energy Cost $ 3,984,002

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 33,006,478 kWh $ 1,631,300 $ 0.049 /kWh

- Demand Charge

 61,285 kW $ 558,531 $ 9.11 /kW

- Electricity Fees

 - $ 49,571 -

Fuel Oil #2

 19,991 MMBtu $ 157,800 $ 7.89 /MMBtu

Fuel Oil #6

 384,636 MMBtu $ 1,586,800 $ 4.13 /MMBtu

TOTAL ENERGY

 742,943 MMBtu $ 3,984,002 $ 5.36 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 385,400 kWh
506,900 kWh		 $ 19,225
$ 25,425		 1.18 %
1.56 %		 $ 0.049 /kWh

- Demand Charge

 -720 kW
0 kW		 $ -6,600
$ 0		 -1.18 %
0.00 %		 $ 9.11 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Fuel Oil #2

 0 MMBtu
0 MMBtu		 $ 0
$ 0		 0.00 %
0.00 %		 $ 7.89 /MMBtu

Fuel Oil #6

 86,998 MMBtu
20,548 MMBtu		 $ 358,700
$ 84,700		 22.61 %
5.34 %		 $ 4.13 /MMBtu

TOTAL ENERGY

 90,949 MMBtu
25,744 MMBtu		 $ 371,325
$ 110,125		 9.32 %
2.76 %		 $ 5.36 /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 $ 250,000 $ 241,800 1.03
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 -513,200 kWh $ -25,600 $ 0.049 /kWh

- Demand Charge

 -720 kW $ -6,600 $ 9.11 /kW

Fuel Oil #6

 66,450 MMBtu $ 274,000 $ 4.13 /MMBtu

TOTAL ENERGY

 61,190 MMBtu $ 241,800 -
02 view
details		 USE FLUE GAS HEAT TO PREHEAT BOILER FEEDWATER 2.2412 I $ 1,500 $ 84,500 0.02
Energy Sources Yearly Reduction Yearly Savings Unit Price

Fuel Oil #6

 20,500 MMBtu $ 84,500 $ 4.13 /MMBtu

TOTAL ENERGY

 20,500 MMBtu $ 84,500 -
03 view
details		 MINIMIZE WATER USAGE 3.4151 I $ 0 $ 25,000 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Water Consumption

 - $ 25,000 -

TOTAL PRODUCTON

 - $ 25,000 -
04 view
details		 REPLACE THE CHLORINATION STAGE WITH AN OXYGEN OR OZONE STAGE 3.4141 N $ 5,000 $ 24,500 0.20
Energy Sources Yearly Reduction Yearly Savings Unit Price

Ancillary Material Cost

 - $ -13,500 -

Water Consumption

 - $ 38,000 -

TOTAL PRODUCTON

 - $ 24,500 -
05 view
details		 USE MULTIPLE SPEED MOTORS OR AFD FOR VARIABLE PUMP, BLOWER AND COMPRESSOR LOADS 2.4141 N $ 20,000 $ 10,500 1.90
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 211,000 kWh $ 10,500 $ 0.049 /kWh

TOTAL ENERGY

 2,163 MMBtu $ 10,500 -
06 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 700 $ 6,025 0.12
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 120,500 kWh $ 6,025 $ 0.049 /kWh

TOTAL ENERGY

 1,235 MMBtu $ 6,025 -
07 view
details		 USE MULTIPLE SPEED MOTORS OR AFD FOR VARIABLE PUMP, BLOWER AND COMPRESSOR LOADS 2.4141 I $ 0 $ 5,800 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 116,000 kWh $ 5,800 $ 0.049 /kWh

TOTAL ENERGY

 1,189 MMBtu $ 5,800 -
08 view
details		 USE MULTIPLE SPEED MOTORS OR AFD FOR VARIABLE PUMP, BLOWER AND COMPRESSOR LOADS 2.4141 I $ 12,000 $ 5,000 2.40
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 99,000 kWh $ 5,000 $ 0.049 /kWh

TOTAL ENERGY

 1,015 MMBtu $ 5,000 -
09 view
details		 USE MULTIPLE SPEED MOTORS OR AFD FOR VARIABLE PUMP, BLOWER AND COMPRESSOR LOADS 2.4141 I $ 8,000 $ 4,900 1.63
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 97,400 kWh $ 4,900 $ 0.049 /kWh

TOTAL ENERGY

 998 MMBtu $ 4,900 -
10 view
details		 USE MULTIPLE SPEED MOTORS OR AFD FOR VARIABLE PUMP, BLOWER AND COMPRESSOR LOADS 2.4141 I $ 7,500 $ 3,700 2.03
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 74,000 kWh $ 3,700 $ 0.049 /kWh

TOTAL ENERGY

 759 MMBtu $ 3,700 -
11 view
details		 USE MULTIPLE SPEED MOTORS OR AFD FOR VARIABLE PUMP, BLOWER AND COMPRESSOR LOADS 2.4141 N $ 8,000 $ 3,000 2.67
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 60,500 kWh $ 3,000 $ 0.049 /kWh

TOTAL ENERGY

 620 MMBtu $ 3,000 -
12 view
details		 USE MULTIPLE SPEED MOTORS OR AFD FOR VARIABLE PUMP, BLOWER AND COMPRESSOR LOADS 2.4141 N $ 8,000 $ 3,000 2.67
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 62,500 kWh $ 3,000 $ 0.049 /kWh

TOTAL ENERGY

 641 MMBtu $ 3,000 -
13 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 N $ 1,000 $ 2,900 0.34
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 57,700 kWh $ 2,900 $ 0.049 /kWh

TOTAL ENERGY

 591 MMBtu $ 2,900 -
14 view
details		 INSULATE STEAM / HOT WATER LINES 2.2131 I $ 150 $ 200 0.75
Energy Sources Yearly Reduction Yearly Savings Unit Price

Fuel Oil #6

 48 MMBtu $ 200 $ 4.13 /MMBtu

TOTAL ENERGY

 48 MMBtu $ 200 -