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

Industrial Assessment Centers

Assessment #OR0509


Assessment Year 2006
SIC 3365
SIC Description Aluminum Foundries
NAICS 331524
NAICS Description Aluminum Foundries (except Die-Casting)
Principal Product Aluminum Castings
Sales $ 14,500,000
# of Employees 90
Plant Area (Sq.Ft.) 85,000
Annual Production 2,584,000 Pounds
Production Hrs. Annual 7,752
Location (State) WA
Yearly Energy Cost $ 643,575

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 10,033,444 kWh $ 112,732 $ 0.011 /kWh

- Demand Charge

 25,391 kW $ 81,195 $ 3.20 /kW

- Electricity Fees

 - $ 12,662 -

LPG

 32,423 MMBtu $ 436,986 $ 13.48 /MMBtu

TOTAL ENERGY

 135,266 MMBtu $ 643,575 $ 4.76 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 1,729,980 kWh
1,478,480 kWh		 $ 20,500
$ 17,500		 18.18 %
15.52 %		 $ 0.011 /kWh

- Demand Charge

 2,034 kW
1,667 kW		 $ 6,660
$ 5,460		 8.20 %
6.72 %		 $ 3.20 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

LPG

 4,168 MMBtu
4,168 MMBtu		 $ 56,070
$ 56,070		 12.83 %
12.83 %		 $ 13.48 /MMBtu

TOTAL ENERGY

 21,902 MMBtu
19,324 MMBtu		 $ 83,230
$ 79,030		 12.93 %
12.28 %		 $ 4.76 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 I $ 5,000 $ 2,900 1.72
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 169,800 kWh $ 2,000 $ 0.011 /kWh

- Demand Charge

 254 kW $ 900 $ 3.20 /kW

TOTAL ENERGY

 1,740 MMBtu $ 2,900 -
02 view
details		 INSULATE GLAZING, WALLS, CEILINGS, AND ROOFS 2.7491 I $ 6,800 $ 58,000 0.12
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 162,000 kWh $ 1,930 $ 0.011 /kWh

LPG

 4,168 MMBtu $ 56,070 $ 13.48 /MMBtu

TOTAL ENERGY

 5,829 MMBtu $ 58,000 -
03 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 I $ 2,250 $ 16,200 0.14
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 547,580 kWh $ 6,510 $ 0.011 /kWh

- Demand Charge

 848 kW $ 2,760 $ 3.20 /kW

TOTAL ENERGY

 5,613 MMBtu $ 9,270 -

Administrative Changes

 - $ 6,930 -

TOTAL PRODUCTON

 - $ 6,930 -
04 view
details		 TURN OFF EQUIPMENT WHEN NOT IN USE 2.6218 I $ 240 $ 660 0.36
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 58,500 kWh $ 660 $ 0.011 /kWh

TOTAL ENERGY

 600 MMBtu $ 660 -
05 view
details		 TURN OFF EQUIPMENT WHEN NOT IN USE 2.6218 N $ 650 $ 1,300 0.50
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 72,400 kWh $ 900 $ 0.011 /kWh

- Demand Charge

 115 kW $ 400 $ 3.20 /kW

TOTAL ENERGY

 742 MMBtu $ 1,300 -
06 view
details		 INSULATE BARE EQUIPMENT 2.2511 N $ 1,200 $ 3,000 0.40
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 183,500 kWh $ 2,200 $ 0.011 /kWh

- Demand Charge

 252 kW $ 800 $ 3.20 /kW

TOTAL ENERGY

 1,881 MMBtu $ 3,000 -
07 view
details		 UPGRADE CONTROLS ON COMPRESSORS 2.4224 I $ 11,000 $ 7,000 1.57
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 434,600 kWh $ 5,200 $ 0.011 /kWh

- Demand Charge

 565 kW $ 1,800 $ 3.20 /kW

TOTAL ENERGY

 4,455 MMBtu $ 7,000 -
08 view
details		 INSTALL VINYL STRIP / HIGH SPEED / AIR CURTAIN DOORS 2.7447 I $ 3,000 $ 1,200 2.50
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 106,000 kWh $ 1,200 $ 0.011 /kWh

TOTAL ENERGY

 1,087 MMBtu $ 1,200 -
09 view
details		 ADOPT IN-HOUSE MATERIAL GENERATION 4.2120 N $ 22,000 $ 6,400 3.44
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 -4,400 kWh $ -100 $ 0.011 /kWh

TOTAL ENERGY

 -45 MMBtu $ -100 -

Administrative Changes

 - $ 6,500 -

TOTAL PRODUCTON

 - $ 6,500 -