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

Industrial Technologies Program

Industrial Assessment Centers

Assessment #MA0499


Assessment Year 2001
SIC 3297
SIC Description Nonclay Refractories
NAICS
NAICS Description
Principal Product Refractoty kiln furniture, Blocks and Liners
Sales $ 62,000,000
# of Employees 290
Plant Area (Sq.Ft.) 142,000
Annual Production 25,000,000 Pounds
Production Hrs. Annual 6,500
Location (State) MA
Yearly Energy Cost $ 1,294,528

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 7,701,597 kWh $ 467,113 $ 0.061 /kWh

- Demand Charge

 26,343 kW $ 154,032 $ 5.85 /kW

- Electricity Fees

 - $ 783 -

Natural Gas

 49,725 MMBtu $ 279,092 $ 5.61 /MMBtu

Fuel Oil #2

 53,294 MMBtu $ 349,705 $ 6.56 /MMBtu

Other Energy

 8,857 MMBtu $ 43,803 $ 4.95 /MMBtu

TOTAL ENERGY

 190,817 MMBtu $ 1,294,528 $ 6.78 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 -1,451,499 kWh
0 kWh		 $ -88,460
$ 0		 -18.94 %
0.00 %		 $ 0.061 /kWh

- Demand Charge

 -2,238 kW
0 kW		 $ -13,092
$ 0		 -8.50 %
0.00 %		 $ 5.85 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 1,320 MMBtu
0 MMBtu		 $ 8,145
$ 0		 2.92 %
0.00 %		 $ 5.61 /MMBtu

Fuel Oil #2

 7,458 MMBtu
0 MMBtu		 $ 45,270
$ 0		 12.95 %
0.00 %		 $ 6.56 /MMBtu

Other Energy

 896 MMBtu
0 MMBtu		 $ 4,435
$ 0		 10.12 %
0.00 %		 $ 4.95 /MMBtu

TOTAL ENERGY

 -5,204 MMBtu
0 MMBtu		 $ -43,702
$ 0		 -3.38 %
0.00 %		 $ 6.78 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 ADOPT IN-HOUSE MATERIAL GENERATION 4.2120 N $ 500,000 $ 268,341 1.86
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 -1,633,740 kWh $ -99,567 $ 0.061 /kWh

- Demand Charge

 -2,238 kW $ -13,092 $ 5.85 /kW

TOTAL ENERGY

 -16,746 MMBtu $ -112,659 -

Administrative Changes

 - $ -1,000 -

Ancillary Material Cost

 - $ 382,000 -

TOTAL PRODUCTON

 - $ 381,000 -
02 view
details		 RECOVER HEAT FROM OVEN EXHAUST / KILNS 2.2432 N $ 154,000 $ 45,270 3.40
Energy Sources Yearly Reduction Yearly Savings Unit Price

Fuel Oil #2

 7,458 MMBtu $ 45,270 $ 6.56 /MMBtu

TOTAL ENERGY

 7,458 MMBtu $ 45,270 -
03 view
details		 USE MULTIPLE SPEED MOTORS OR AFD FOR VARIABLE PUMP, BLOWER AND COMPRESSOR LOADS 2.4141 N $ 9,960 $ 7,963 1.25
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 130,645 kWh $ 7,963 $ 0.061 /kWh

TOTAL ENERGY

 1,339 MMBtu $ 7,963 -
04 view
details		 USE MINIMUM SAFE OVEN VENTILATION 2.2212 N $ 14,200 $ 7,334 1.94
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 11,325 kWh $ 690 $ 0.061 /kWh

Natural Gas

 358 MMBtu $ 2,209 $ 5.61 /MMBtu

Other Energy

 896 MMBtu $ 4,435 $ 4.95 /MMBtu

TOTAL ENERGY

 1,370 MMBtu $ 7,334 -
05 view
details		 RECOVER HEAT FROM OVEN EXHAUST / KILNS 2.2432 N $ 12,650 $ 5,936 2.13
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 962 MMBtu $ 5,936 $ 5.61 /MMBtu

TOTAL ENERGY

 962 MMBtu $ 5,936 -
06 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 N $ 255 $ 1,235 0.21
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 20,269 kWh $ 1,235 $ 0.061 /kWh

TOTAL ENERGY

 208 MMBtu $ 1,235 -
07 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 N $ 2,000 $ 1,219 1.64
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 20,002 kWh $ 1,219 $ 0.061 /kWh

TOTAL ENERGY

 205 MMBtu $ 1,219 -