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

Industrial Technologies Program

Industrial Assessment Centers

Assessment #NC0434


Assessment Year 2011
SIC 3564
SIC Description Blowers And Fans
NAICS 333411
NAICS Description Air Purification Equipment Manufacturing
Principal Product Indoor air quality equipment
Sales $ 25,000,000
# of Employees 115
Plant Area (Sq.Ft.) 265,000
Annual Production 25,000 Pieces
Production Hrs. Annual 2,500
Location (State) NC
Yearly Energy Cost $ 365,070

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 3,198,000 kWh $ 170,076 $ 0.053 /kWh

- Demand Charge

 9,800 kW $ 83,312 $ 8.50 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 15,085 MMBtu $ 111,682 $ 7.40 /MMBtu

TOTAL ENERGY

 47,865 MMBtu $ 365,070 $ 7.63 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 310,297 kWh
310,297 kWh		 $ 16,502
$ 16,502		 9.70 %
9.70 %		 $ 0.053 /kWh

- Demand Charge

 1,468 kW
1,468 kW		 $ 12,471
$ 12,471		 14.97 %
14.97 %		 $ 8.50 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 1,285 MMBtu
480 MMBtu		 $ 9,509
$ 3,552		 8.51 %
3.18 %		 $ 7.40 /MMBtu

TOTAL ENERGY

 4,466 MMBtu
3,661 MMBtu		 $ 38,482
$ 32,525		 10.54 %
8.91 %		 $ 7.63 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 RECOVER HEAT FROM AIR COMPRESSOR 2.2434 I $ 2,127 $ 3,138 0.68
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 424 MMBtu $ 3,138 $ 7.40 /MMBtu

TOTAL ENERGY

 424 MMBtu $ 3,138 -
02 view
details		 ELIMINATE OR REDUCE COMPRESSED AIR USED FOR COOLING, AGITATING LIQUIDS, MOVING PRODUCT, OR DRYING 2.4232 I $ 14,895 $ 3,152 4.73
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 36,443 kWh $ 1,938 $ 0.053 /kWh

- Demand Charge

 143 kW $ 1,214 $ 8.50 /kW

TOTAL ENERGY

 374 MMBtu $ 3,152 -
03 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 I $ 1,000 $ 1,424 0.70
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 16,866 kWh $ 897 $ 0.053 /kWh

- Demand Charge

 62 kW $ 527 $ 8.50 /kW

TOTAL ENERGY

 173 MMBtu $ 1,424 -
04 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 100 $ 142 0.70
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 6,705 kWh $ 357 $ 0.053 /kWh

- Demand Charge

 24 kW $ 205 $ 8.50 /kW

TOTAL ENERGY

 69 MMBtu $ 562 -

Personnel Changes

 - $ -300 -

Ancillary Material Cost

 - $ -120 -

TOTAL PRODUCTON

 - $ -420 -
05 view
details		 REPLACE BOILER 2.1224 N $ 26,400 $ 5,957 4.43
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 805 MMBtu $ 5,957 $ 7.40 /MMBtu

TOTAL ENERGY

 805 MMBtu $ 5,957 -
06 view
details		 COVER OPEN TANKS 2.2514 I $ 908 $ 414 2.19
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 56 MMBtu $ 414 $ 7.40 /MMBtu

TOTAL ENERGY

 56 MMBtu $ 414 -
07 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 32,453 $ 19,609 1.66
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 208,658 kWh $ 11,096 $ 0.053 /kWh

- Demand Charge

 1,002 kW $ 8,513 $ 8.50 /kW

TOTAL ENERGY

 2,139 MMBtu $ 19,609 -
08 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 I $ 10,660 $ 3,087 3.45
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 33,915 kWh $ 1,804 $ 0.053 /kWh

- Demand Charge

 163 kW $ 1,383 $ 8.50 /kW

TOTAL ENERGY

 348 MMBtu $ 3,187 -

Ancillary Material Cost

 - $ -100 -

TOTAL PRODUCTON

 - $ -100 -
09 view
details		 REPLACE ELECTRIC MOTOR WITH FOSSIL FUEL ENGINE 2.4134 I $ 876 $ 1,039 0.84
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 7,710 kWh $ 410 $ 0.053 /kWh

- Demand Charge

 74 kW $ 629 $ 8.50 /kW

TOTAL ENERGY

 79 MMBtu $ 1,039 -