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

Industrial Technologies Program

Industrial Assessment Centers

Assessment #NC0383


Assessment Year 2008
SIC 2869
SIC Description Industrial Organic Chemicals, Nec
NAICS 325199
NAICS Description All Other Basic Organic Chemical Manufacturing
Principal Product Specialty chemicals
Sales $ 20,000,000
# of Employees 116
Plant Area (Sq.Ft.) 300,000
Annual Production 1,000,000 Pounds
Production Hrs. Annual 8,760
Location (State) VA
Yearly Energy Cost $ 1,711,463

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 12,526,240 kWh $ 554,374 $ 0.044 /kWh

- Demand Charge

 23,086 kW $ 228,551 $ 9.90 /kW

- Electricity Fees

 - $ 1,837 -

Natural Gas

 107,361 MMBtu $ 926,701 $ 8.63 /MMBtu

TOTAL ENERGY

 235,755 MMBtu $ 1,711,463 $ 7.26 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 391,783 kWh
274,209 kWh		 $ 17,339
$ 12,136		 3.13 %
2.19 %		 $ 0.044 /kWh

- Demand Charge

 557 kW
382 kW		 $ 5,522
$ 3,782		 2.42 %
1.65 %		 $ 9.90 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 7,636 MMBtu
5,590 MMBtu		 $ 112,245
$ 82,165		 12.11 %
8.87 %		 $ 8.63 /MMBtu

TOTAL ENERGY

 11,651 MMBtu
8,400 MMBtu		 $ 135,106
$ 98,083		 7.89 %
5.73 %		 $ 7.26 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 ESTABLISH BURNER MAINTENANCE SCHEDULE FOR BOILERS 2.1231 I $ 1,000 $ 16,582 0.06
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,128 MMBtu $ 16,582 $ 8.63 /MMBtu

TOTAL ENERGY

 1,128 MMBtu $ 16,582 -
02 view
details		 USE MOST EFFICIENT EQUIPMENT AT IT'S MAXIMUM CAPACITY AND LESS EFFICIENT EQUIPMENT ONLY WHEN NECESSARY 2.6221 I $ 0 $ 38,474 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,257 MMBtu $ 18,474 $ 8.63 /MMBtu

TOTAL ENERGY

 1,257 MMBtu $ 18,474 -

One-time Revenue or Avoided Cost

 - $ 20,000 -

TOTAL PRODUCTON

 - $ 20,000 -
03 view
details		 USE FLUE GAS HEAT TO PREHEAT BOILER FEEDWATER 2.2412 I $ 50,000 $ 42,558 1.17
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 2,895 MMBtu $ 42,558 $ 8.63 /MMBtu

TOTAL ENERGY

 2,895 MMBtu $ 42,558 -
04 view
details		 INCREASE AMOUNT OF CONDENSATE RETURNED 2.2121 N $ 30,000 $ 19,037 1.58
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,295 MMBtu $ 19,037 $ 8.63 /MMBtu

TOTAL ENERGY

 1,295 MMBtu $ 19,037 -
05 view
details		 INSTALL DE-AERATOR IN PLACE OF CONDENSATE TANK 2.2124 I $ 10,000 $ 4,551 2.20
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 310 MMBtu $ 4,551 $ 8.63 /MMBtu

TOTAL ENERGY

 310 MMBtu $ 4,551 -
06 view
details		 UTILIZE A LESS EXPENSIVE COOLING METHOD 2.2628 N $ 20,000 $ 4,245 4.71
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 73,100 kWh $ 3,235 $ 0.044 /kWh

- Demand Charge

 102 kW $ 1,010 $ 9.90 /kW

TOTAL ENERGY

 749 MMBtu $ 4,245 -
07 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 N $ 50 $ 1,848 0.03
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 31,820 kWh $ 1,408 $ 0.044 /kWh

- Demand Charge

 44 kW $ 440 $ 9.90 /kW

TOTAL ENERGY

 326 MMBtu $ 1,848 -
08 view
details		 RECOVER HEAT FROM AIR COMPRESSOR 2.2434 N $ 6,150 $ 11,043 0.56
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 751 MMBtu $ 11,043 $ 8.63 /MMBtu

TOTAL ENERGY

 751 MMBtu $ 11,043 -
09 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 100 $ 1,623 0.06
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 43,443 kWh $ 1,923 $ 0.044 /kWh

- Demand Charge

 61 kW $ 600 $ 9.90 /kW

TOTAL ENERGY

 445 MMBtu $ 2,523 -

Personnel Changes

 - $ -600 -

Ancillary Material Cost

 - $ -300 -

TOTAL PRODUCTON

 - $ -900 -
10 view
details		 DEVELOP A REPAIR/REPLACE POLICY 2.4151 I $ 11,589 $ 11,700 0.99
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 201,468 kWh $ 8,916 $ 0.044 /kWh

- Demand Charge

 281 kW $ 2,784 $ 9.90 /kW

TOTAL ENERGY

 2,065 MMBtu $ 11,700 -
11 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 1,497 $ 1,695 0.88
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 29,298 kWh $ 1,297 $ 0.044 /kWh

- Demand Charge

 40 kW $ 398 $ 9.90 /kW

TOTAL ENERGY

 300 MMBtu $ 1,695 -
12 view
details		 UTILIZE DAYLIGHT WHENEVER POSSIBLE IN LIEU OF ARTIFICIAL LIGHT 2.7121 N $ 750 $ 850 0.88
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 12,654 kWh $ 560 $ 0.044 /kWh

- Demand Charge

 29 kW $ 290 $ 9.90 /kW

TOTAL ENERGY

 130 MMBtu $ 850 -