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

Industrial Technologies Program

Industrial Assessment Centers

Assessment #MZ0062


Assessment Year 2011
SIC 3499
SIC Description Fabricated Metal Products, Nec
NAICS 332999
NAICS Description All Other Miscellaneous Fabricated Metal Product Manufacturing
Principal Product Steel couplings for hydraulic hoses
Sales $ 50,000,000
# of Employees 100
Plant Area (Sq.Ft.) 80,000
Annual Production 60,000,000 Pieces
Production Hrs. Annual 8,000
Location (State) MO
Yearly Energy Cost $ 808,876

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 7,709,300 kWh $ 462,192 $ 0.060 /kWh

- Demand Charge

 15,887 kW $ 127,096 $ 8.00 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 31,823 MMBtu $ 219,588 $ 6.90 /MMBtu

TOTAL ENERGY

 110,844 MMBtu $ 808,876 $ 7.30 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 2,380,324 kWh
1,084,354 kWh		 $ 140,519
$ 62,761		 30.40 %
13.58 %		 $ 0.060 /kWh

- Demand Charge

 2,504 kW
632 kW		 $ 20,040
$ 5,064		 15.77 %
3.98 %		 $ 8.00 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 10,530 MMBtu
7,569 MMBtu		 $ 72,663
$ 52,233		 33.09 %
23.79 %		 $ 6.90 /MMBtu

TOTAL ENERGY

 34,929 MMBtu
18,684 MMBtu		 $ 233,221
$ 120,057		 28.83 %
14.84 %		 $ 7.30 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 I $ 1,160 $ 7,242 0.16
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 120,706 kWh $ 7,242 $ 0.060 /kWh

TOTAL ENERGY

 1,237 MMBtu $ 7,242 -
02 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 I $ 49,280 $ 31,772 1.55
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 420,272 kWh $ 25,216 $ 0.060 /kWh

- Demand Charge

 819 kW $ 6,556 $ 8.00 /kW

TOTAL ENERGY

 4,308 MMBtu $ 31,772 -
03 view
details		 INSTALL OCCUPANCY SENSORS 2.7135 N $ 1,840 $ 1,292 1.42
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 21,535 kWh $ 1,292 $ 0.060 /kWh

TOTAL ENERGY

 221 MMBtu $ 1,292 -
04 view
details		 INSTALL SPECTRAL REFLECTORS / DELAMP 2.7144 I $ 100 $ 1,360 0.07
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 18,880 kWh $ 1,133 $ 0.060 /kWh

- Demand Charge

 28 kW $ 227 $ 8.00 /kW

TOTAL ENERGY

 194 MMBtu $ 1,360 -
05 view
details		 USE PROPER THICKNESS OF INSULATION ON BUILDING ENVELOPE 2.7492 N $ 1,498 $ 866 1.73
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 126 MMBtu $ 866 $ 6.90 /MMBtu

TOTAL ENERGY

 126 MMBtu $ 866 -
06 view
details		 USE WASTE HEAT TO PRODUCE STEAM TO DRIVE A STEAM TURBINE-GENERATOR 2.3412 N $ 250,000 $ 89,844 2.78
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 1,247,803 kWh $ 74,868 $ 0.060 /kWh

- Demand Charge

 1,872 kW $ 14,976 $ 8.00 /kW

TOTAL ENERGY

 12,790 MMBtu $ 89,844 -
07 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 1,300 $ 26,441 0.05
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 440,690 kWh $ 26,441 $ 0.060 /kWh

TOTAL ENERGY

 4,517 MMBtu $ 26,441 -
08 view
details		 ELIMINATE OR REDUCE COMPRESSED AIR USED FOR COOLING, AGITATING LIQUIDS, MOVING PRODUCT, OR DRYING 2.4232 I $ 15,000 $ 8,105 1.85
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 112,055 kWh $ 6,723 $ 0.060 /kWh

- Demand Charge

 173 kW $ 1,382 $ 8.00 /kW

TOTAL ENERGY

 1,149 MMBtu $ 8,105 -
09 view
details		 ELIMINATE OR REDUCE COMPRESSED AIR USED FOR COOLING, AGITATING LIQUIDS, MOVING PRODUCT, OR DRYING 2.4232 I $ 9,000 $ 4,053 2.22
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 56,028 kWh $ 3,362 $ 0.060 /kWh

- Demand Charge

 86 kW $ 691 $ 8.00 /kW

TOTAL ENERGY

 574 MMBtu $ 4,053 -
10 view
details		 USE FLUE GAS HEAT TO PREHEAT BOILER FEEDWATER 2.2412 N $ 30,000 $ 19,502 1.54
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 2,826 MMBtu $ 19,502 $ 6.90 /MMBtu

TOTAL ENERGY

 2,826 MMBtu $ 19,502 -
11 view
details		 USE WASTE HEAT FROM HOT FLUE GASES TO PREHEAT COMBUSTION AIR 2.2411 I $ 10,000 $ 17,836 0.56
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 2,584 MMBtu $ 17,836 $ 6.90 /MMBtu

TOTAL ENERGY

 2,584 MMBtu $ 17,836 -
12 view
details		 USE PROPER THICKNESS OF INSULATION ON BUILDING ENVELOPE 2.7492 N $ 60 $ 62 0.97
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 9 MMBtu $ 62 $ 6.90 /MMBtu

TOTAL ENERGY

 9 MMBtu $ 62 -
13 view
details		 USE SEPARATE SWITCHES ON PERIMETER LIGHTING WHICH MAY BE TURNED OFF WHEN NATURAL LIGHT IS AVAILABLE 2.7133 I $ 300 $ 91 3.30
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 1,512 kWh $ 91 $ 0.060 /kWh

TOTAL ENERGY

 15 MMBtu $ 91 -
14 view
details		 REPLACE FOSSIL FUEL EQUIPMENT WITH ELECTRICAL EQUIPMENT 2.1321 I $ 150,000 $ 11,657 12.87
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 -315,789 kWh $ -18,947 $ 0.060 /kWh

- Demand Charge

 -474 kW $ -3,792 $ 8.00 /kW

Natural Gas

 4,985 MMBtu $ 34,397 $ 6.90 /MMBtu

TOTAL ENERGY

 1,748 MMBtu $ 11,657 -
15 view
details		 USE MULTIPLE SPEED MOTORS OR AFD FOR VARIABLE PUMP, BLOWER AND COMPRESSOR LOADS 2.4141 N $ 1,500 $ 1,598 0.94
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 26,632 kWh $ 1,598 $ 0.060 /kWh

TOTAL ENERGY

 273 MMBtu $ 1,598 -
16 view
details		 UPGRADE CONTROLS ON COMPRESSORS 2.4224 I $ 18,000 $ 11,500 1.57
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 230,000 kWh $ 11,500 $ 0.060 /kWh

TOTAL ENERGY

 2,358 MMBtu $ 11,500 -