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

Industrial Assessment Centers

Assessment #MA0622


Assessment Year 2007
SIC 2621
SIC Description Paper Mills
NAICS 322121
NAICS Description Paper (except Newsprint) Mills
Principal Product tissue paper
Sales $ 4,000,000
# of Employees 121
Plant Area (Sq.Ft.) 208,000
Annual Production 43,800 Tons
Production Hrs. Annual 8,760
Location (State) MA
Yearly Energy Cost $ 10,674,270

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 46,682,650 kWh $ 6,189,578 $ 0.133 /kWh

- Demand Charge

 76,053 kW $ 346,041 $ 4.55 /kW

- Electricity Fees

 - $ 848 -

Fuel Oil #2

 73,065 MMBtu $ 1,156,108 $ 15.82 /MMBtu

Fuel Oil #6

 342,186 MMBtu $ 2,981,695 $ 8.71 /MMBtu

TOTAL ENERGY

 893,748 MMBtu $ 10,674,270 $ 11.94 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 3,219,193 kWh
2,618,244 kWh		 $ 427,547
$ 347,715		 6.91 %
5.62 %		 $ 0.133 /kWh

- Demand Charge

 4,392 kW
3,498 kW		 $ 19,983
$ 15,915		 5.77 %
4.60 %		 $ 4.55 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Fuel Oil #2

 41,876 MMBtu
41,876 MMBtu		 $ 662,479
$ 662,479		 57.30 %
57.30 %		 $ 15.82 /MMBtu

Fuel Oil #6

 396,585 MMBtu
344,616 MMBtu		 $ 3,451,255
$ 3,001,605		 115.75 %
100.67 %		 $ 8.71 /MMBtu

TOTAL ENERGY

 81,365 MMBtu
23,236 MMBtu		 $ 3,445,601
$ 2,912,051		 32.28 %
27.28 %		 $ 11.94 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 BURN A LESS EXPENSIVE GRADE OF FUEL 2.1331 I $ 4,120,500 $ 1,852,277 2.22
Energy Sources Yearly Reduction Yearly Savings Unit Price

Fuel Oil #6

 342,186 MMBtu $ 2,980,440 $ 8.71 /MMBtu

Wood

 -390,092 MMBtu $ -1,115,663 $ 0.00 /MMBtu

TOTAL ENERGY

 -47,906 MMBtu $ 1,864,777 -

Ancillary Material Cost

 - $ -12,500 -

TOTAL PRODUCTON

 - $ -12,500 -
02 view
details		 USE HOT PROCESS FLUIDS TO PREHEAT INCOMING PROCESS FLUIDS 2.2444 I $ 423,075 $ 653,801 0.65
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 -65,350 kWh $ -8,678 $ 0.133 /kWh

Fuel Oil #2

 41,876 MMBtu $ 662,479 $ 15.82 /MMBtu

TOTAL ENERGY

 41,206 MMBtu $ 653,801 -
03 view
details		 RECOVER HEAT FROM HOT WASTE WATER 2.2446 N $ 250,000 $ 449,650 0.56
Energy Sources Yearly Reduction Yearly Savings Unit Price

Fuel Oil #6

 51,969 MMBtu $ 449,650 $ 8.71 /MMBtu

TOTAL ENERGY

 51,969 MMBtu $ 449,650 -
04 view
details		 USE OPTIMUM SIZE AND CAPACITY EQUIPMENT 2.4323 I $ 694,400 $ 337,840 2.06
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 2,424,135 kWh $ 321,925 $ 0.133 /kWh

- Demand Charge

 3,498 kW $ 15,915 $ 4.55 /kW

TOTAL ENERGY

 24,847 MMBtu $ 337,840 -
05 view
details		 USE MULTIPLE SPEED MOTORS OR AFD FOR VARIABLE PUMP, BLOWER AND COMPRESSOR LOADS 2.4141 N $ 60,600 $ 67,981 0.89
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 488,949 kWh $ 64,932 $ 0.133 /kWh

- Demand Charge

 670 kW $ 3,049 $ 4.55 /kW

TOTAL ENERGY

 5,012 MMBtu $ 67,981 -
06 view
details		 UPGRADE OBSOLETE EQUIPMENT 2.4321 I $ 111,500 $ 34,468 3.23
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 259,459 kWh $ 34,468 $ 0.133 /kWh

TOTAL ENERGY

 2,659 MMBtu $ 34,468 -
07 view
details		 INSULATE STEAM / HOT WATER LINES 2.2131 I $ 10,000 $ 21,165 0.47
Energy Sources Yearly Reduction Yearly Savings Unit Price

Fuel Oil #6

 2,430 MMBtu $ 21,165 $ 8.71 /MMBtu

TOTAL ENERGY

 2,430 MMBtu $ 21,165 -
08 view
details		 USE MULTIPLE SPEED MOTORS OR AFD FOR VARIABLE PUMP, BLOWER AND COMPRESSOR LOADS 2.4141 N $ 30,500 $ 15,919 1.92
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 112,000 kWh $ 14,900 $ 0.133 /kWh

- Demand Charge

 224 kW $ 1,019 $ 4.55 /kW

TOTAL ENERGY

 1,148 MMBtu $ 15,919 -