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

Industrial Assessment Centers

Assessment #SF0341


Assessment Year 2007
SIC 3339
SIC Description Primary Nonferrous Metals, Nec
NAICS 331419
NAICS Description Primary Smelting and Refining of Nonferrous Metal (except Copper and Aluminum)
Principal Product Investment Castings
Sales $ 40,000,000
# of Employees 200
Plant Area (Sq.Ft.) 65,000
Annual Production 15,000,000 Pieces
Production Hrs. Annual 8,736
Location (State) CA
Yearly Energy Cost $ 1,372,567

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 6,681,600 kWh $ 545,103 $ 0.082 /kWh

- Demand Charge

 17,234 kW $ 291,906 $ 16.94 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 43,923 MMBtu $ 535,558 $ 12.19 /MMBtu

TOTAL ENERGY

 112,409 MMBtu $ 1,372,567 $ 12.21 /MMBtu

Solid Waste (non-haz)

 88,880 lbs $ 43,062 $ 0 /lbs

Recommended Reduction in Usage & Costs

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

Electricity

 426,182 kWh
405,581 kWh		 $ 29,450
$ 27,773		 5.40 %
5.10 %		 $ 0.082 /kWh

- Demand Charge

 16,488 kW
16,467 kW		 $ 8,016
$ 7,676		 2.75 %
2.63 %		 $ 16.94 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 6,737 MMBtu
6,467 MMBtu		 $ 80,742
$ 77,744		 15.08 %
14.52 %		 $ 12.19 /MMBtu

TOTAL ENERGY

 11,105 MMBtu
10,624 MMBtu		 $ 118,208
$ 113,193		 8.61 %
8.25 %		 $ 12.21 /MMBtu

Solid Waste (non-haz)

 26,620 lbs
26,620 lbs		 $ 17,456
$ 17,456		 40.54 %
40.54 %		 $ 0 /lbs

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 ANALYZE FLUE GAS FOR PROPER AIR/FUEL RATIO 2.1233 I $ 0 $ 5,716 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 559 MMBtu $ 5,716 $ 12.19 /MMBtu

TOTAL ENERGY

 559 MMBtu $ 5,716 -
02 view
details		 REPAIR LEAKS IN LINES AND VALVES 2.2133 N $ 0 $ 2,998 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 270 MMBtu $ 2,998 $ 12.19 /MMBtu

TOTAL ENERGY

 270 MMBtu $ 2,998 -
03 view
details		 REPAIR LEAKS IN LINES AND VALVES 2.2133 I $ 0 $ 529 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 14,036 kWh $ 529 $ 0.082 /kWh

TOTAL ENERGY

 144 MMBtu $ 529 -
04 view
details		 USE MOST EFFICIENT TYPE OF ELECTRIC MOTORS 2.4133 I $ 919 $ 4,392 0.21
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 94,072 kWh $ 3,307 $ 0.082 /kWh

- Demand Charge

 67 kW $ 1,085 $ 16.94 /kW

TOTAL ENERGY

 964 MMBtu $ 4,392 -
05 view
details		 CHANGE RATE SCHEDULES OR OTHER CHANGES IN UTILITY SERVICE 2.8114 N $ 37,915 $ 99,580 0.38
Energy Sources Yearly Reduction Yearly Savings Unit Price

One-time Revenue or Avoided Cost

 - $ 99,580 -

TOTAL PRODUCTON

 - $ 99,580 -
06 view
details		 USE ADJUSTABLE FREQUENCY DRIVE TO REPLACE MECHANICAL DRIVE 2.4144 I $ 9,373 $ 18,960 0.49
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 173,409 kWh $ 13,954 $ 0.082 /kWh

- Demand Charge

 298 kW $ 5,006 $ 16.94 /kW

TOTAL ENERGY

 1,777 MMBtu $ 18,960 -
07 view
details		 INSTALL OUTSIDE AIR DAMPER / ECONOMIZER ON HVAC UNIT 2.7241 I $ 15,000 $ 20,686 0.73
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,697 MMBtu $ 20,686 $ 12.19 /MMBtu

TOTAL ENERGY

 1,697 MMBtu $ 20,686 -
08 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 1,620 $ 1,585 1.02
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Demand Charge

 16,102 kW $ 1,585 $ 16.94 /kW

TOTAL ENERGY

 0 MMBtu $ 1,585 -
09 view
details		 USE HEAT FROM BOILER BLOWDOWN TO PREHEAT BOILER FEED WATER 2.1243 I $ 60,000 $ 51,342 1.17
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 4,211 MMBtu $ 51,342 $ 12.19 /MMBtu

TOTAL ENERGY

 4,211 MMBtu $ 51,342 -
10 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 N $ 1,512 $ 1,113 1.36
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 9,362 kWh $ 773 $ 0.082 /kWh

- Demand Charge

 21 kW $ 340 $ 16.94 /kW

TOTAL ENERGY

 96 MMBtu $ 1,113 -
11 view
details		 USE ADJUSTABLE FREQUENCY DRIVE TO REPLACE MECHANICAL DRIVE 2.4144 I $ 19,920 $ 9,983 2.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 124,064 kWh $ 9,983 $ 0.082 /kWh

TOTAL ENERGY

 1,272 MMBtu $ 9,983 -
12 view
details		 USE ADJUSTABLE FREQUENCY DRIVE TO REPLACE MECHANICAL DRIVE 2.4144 N $ 2,887 $ 904 3.19
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 11,239 kWh $ 904 $ 0.082 /kWh

TOTAL ENERGY

 115 MMBtu $ 904 -
13 view
details		 REUSE / RECYCLE/ SELL RUBBER PRODUCTS 3.5218 I $ 0 $ 17,456 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Solid Waste (non-haz)

 26,620 lbs $ 17,456 $ 0 /lbs

TOTAL WASTE

 - $ 17,456 -