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

Industrial Technologies Program

Industrial Assessment Centers

Assessment #MA0511


Assessment Year 2002
SIC 3341
SIC Description Secondary Nonferrous Metals
NAICS
NAICS Description
Principal Product Bonded metals
Sales $ 22,000,000
# of Employees 80
Plant Area (Sq.Ft.) 79,700
Annual Production 3,800,000 Pounds
Production Hrs. Annual 2,750
Location (State) MA
Yearly Energy Cost $ 411,298

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 2,797,600 kWh $ 207,917 $ 0.074 /kWh

- Demand Charge

 11,864 kW $ 97,878 $ 8.25 /kW

- Electricity Fees

 - $ 14,168 -

Natural Gas

 7,369 MMBtu $ 91,335 $ 12.39 /MMBtu

TOTAL ENERGY

 36,044 MMBtu $ 411,298 $ 11.41 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 55,901 kWh
55,901 kWh		 $ 3,897
$ 3,897		 1.87 %
1.87 %		 $ 0.074 /kWh

- Demand Charge

 4,666 kW
4,666 kW		 $ 38,495
$ 38,495		 39.33 %
39.33 %		 $ 8.25 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 982 MMBtu
982 MMBtu		 $ 10,589
$ 10,589		 11.59 %
11.59 %		 $ 12.39 /MMBtu

TOTAL ENERGY

 1,555 MMBtu
1,555 MMBtu		 $ 52,981
$ 52,981		 12.88 %
12.88 %		 $ 11.41 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 RESCHEDULE PLANT OPERATIONS OR REDUCE LOAD TO AVOID PEAKS 2.3131 I $ 4,090 $ 38,495 0.11
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Demand Charge

 4,666 kW $ 38,495 $ 8.25 /kW

TOTAL ENERGY

 0 MMBtu $ 38,495 -
02 view
details		 APPLY FOR INVESTMENT INCENTIVES 4.8120 I $ 0 $ 15,314 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Administrative Changes

 - $ 15,314 -

TOTAL PRODUCTON

 - $ 15,314 -
03 view
details		 REDUCE SPACE CONDITIONING DURING NON-WORKING HOURS 2.7224 I $ 14,100 $ 10,764 1.31
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 5,605 kWh $ 391 $ 0.074 /kWh

Natural Gas

 962 MMBtu $ 10,373 $ 12.39 /MMBtu

TOTAL ENERGY

 1,019 MMBtu $ 10,764 -
04 view
details		 USE MULTIPLE SPEED MOTORS OR AFD FOR VARIABLE PUMP, BLOWER AND COMPRESSOR LOADS 2.4141 I $ 6,950 $ 4,282 1.62
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 39,909 kWh $ 2,782 $ 0.074 /kWh

TOTAL ENERGY

 409 MMBtu $ 2,782 -

Administrative Changes

 - $ 1,500 -

TOTAL PRODUCTON

 - $ 1,500 -
05 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 I $ 0 $ 605 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 8,678 kWh $ 605 $ 0.074 /kWh

TOTAL ENERGY

 89 MMBtu $ 605 -
06 view
details		 PAY BILLS ON TIME TO AVOID LATE FEES 4.8210 I $ 0 $ 483 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Administrative Changes

 - $ 483 -

TOTAL PRODUCTON

 - $ 483 -
07 view
details		 TURN OFF EQUIPMENT WHEN NOT IN USE 2.6218 I $ 0 $ 249 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 477 kWh $ 33 $ 0.074 /kWh

Natural Gas

 20 MMBtu $ 216 $ 12.39 /MMBtu

TOTAL ENERGY

 25 MMBtu $ 249 -
08 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 I $ 350 $ 86 4.07
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 1,232 kWh $ 86 $ 0.074 /kWh

TOTAL ENERGY

 13 MMBtu $ 86 -