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

Industrial Assessment Centers

Assessment #SF0349


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 $ 42,000,000
# of Employees 250
Plant Area (Sq.Ft.) 55,000
Annual Production 200,000 Pieces
Production Hrs. Annual 8,736
Location (State) NV
Yearly Energy Cost $ 1,004,385

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 5,664,240 kWh $ 496,733 $ 0.088 /kWh

- Demand Charge

 15,372 kW $ 166,986 $ 10.86 /kW

- Electricity Fees

 - $ 39,414 -

Natural Gas

 25,304 MMBtu $ 301,252 $ 11.91 /MMBtu

TOTAL ENERGY

 83,362 MMBtu $ 1,004,385 $ 12.05 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 784,334 kWh
130,507 kWh		 $ 64,645
$ 11,088		 13.01 %
2.23 %		 $ 0.088 /kWh

- Demand Charge

 471 kW
161 kW		 $ 5,093
$ 1,738		 3.05 %
1.04 %		 $ 10.86 /kW

- Electricity Fees

 - $ 8,751
$ 0		 22.20 %
0.00 %		 -

Natural Gas

 2,845 MMBtu
588 MMBtu		 $ 33,739
$ 6,853		 11.20 %
2.27 %		 $ 11.91 /MMBtu

TOTAL ENERGY

 10,884 MMBtu
1,925 MMBtu		 $ 112,228
$ 19,679		 11.17 %
1.96 %		 $ 12.05 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 REPAIR LEAKS IN LINES AND VALVES 2.2133 I $ 0 $ 6,853 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 588 MMBtu $ 6,853 $ 11.91 /MMBtu

TOTAL ENERGY

 588 MMBtu $ 6,853 -
02 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 N $ 150 $ 6,603 0.02
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 64,650 kWh $ 5,641 $ 0.088 /kWh

- Demand Charge

 89 kW $ 962 $ 10.86 /kW

TOTAL ENERGY

 663 MMBtu $ 6,603 -
03 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 0 $ 1,755 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 23,554 kWh $ 1,755 $ 0.088 /kWh

TOTAL ENERGY

 241 MMBtu $ 1,755 -
04 view
details		 USE MULTIPLE SPEED MOTORS OR AFD FOR VARIABLE PUMP, BLOWER AND COMPRESSOR LOADS 2.4141 N $ 10,019 $ 19,139 0.52
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 259,384 kWh $ 19,139 $ 0.088 /kWh

TOTAL ENERGY

 2,659 MMBtu $ 19,139 -
05 view
details		 INSTALL OCCUPANCY SENSORS 2.7135 I $ 1,992 $ 3,490 0.57
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 32,303 kWh $ 2,819 $ 0.088 /kWh

- Demand Charge

 62 kW $ 671 $ 10.86 /kW

TOTAL ENERGY

 331 MMBtu $ 3,490 -
06 view
details		 UTILIZE CONTROLS TO OPERATE EQUIPMENT ONLY WHEN NEEDED 2.6231 I $ 757 $ 725 1.04
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 8,309 kWh $ 725 $ 0.088 /kWh

TOTAL ENERGY

 85 MMBtu $ 725 -
07 view
details		 REPLACE ELECTRICALLY-OPERATED EQUIPMENT WITH FOSSIL FUEL EQUIPMENT 2.1311 N $ 8,646 $ 7,644 1.13
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 153,753 kWh $ 13,416 $ 0.088 /kWh

- Demand Charge

 221 kW $ 2,393 $ 10.86 /kW

Natural Gas

 -686 MMBtu $ -8,165 $ 11.91 /MMBtu

TOTAL ENERGY

 890 MMBtu $ 7,644 -
08 view
details		 UTILIZE CONTROLS TO OPERATE EQUIPMENT ONLY WHEN NEEDED 2.6231 N $ 2,339 $ 2,042 1.15
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 23,404 kWh $ 2,042 $ 0.088 /kWh

TOTAL ENERGY

 240 MMBtu $ 2,042 -
09 view
details		 COVER OPEN TANKS 2.2514 N $ 14,940 $ 12,984 1.15
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 148,792 kWh $ 12,984 $ 0.088 /kWh

TOTAL ENERGY

 1,525 MMBtu $ 12,984 -
10 view
details		 USE MULTIPLE SPEED MOTORS OR AFD FOR VARIABLE PUMP, BLOWER AND COMPRESSOR LOADS 2.4141 I $ 4,281 $ 3,554 1.20
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 40,732 kWh $ 3,554 $ 0.088 /kWh

TOTAL ENERGY

 418 MMBtu $ 3,554 -
11 view
details		 USE WASTE HEAT FROM HOT FLUE GASES TO PREHEAT COMBUSTION AIR 2.2411 N $ 52,080 $ 31,597 1.65
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 2,653 MMBtu $ 31,597 $ 11.91 /MMBtu

TOTAL ENERGY

 2,653 MMBtu $ 31,597 -
12 view
details		 USE PHOTOCELL CONTROLS 2.7134 I $ 9,569 $ 3,302 2.90
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 25,609 kWh $ 2,235 $ 0.088 /kWh

- Demand Charge

 99 kW $ 1,067 $ 10.86 /kW

TOTAL ENERGY

 262 MMBtu $ 3,302 -
13 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 N $ 980 $ 335 2.93
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 3,844 kWh $ 335 $ 0.088 /kWh

TOTAL ENERGY

 39 MMBtu $ 335 -
14 view
details		 USE FLUE GAS HEAT TO PREHEAT BOILER FEEDWATER 2.2412 N $ 11,000 $ 3,454 3.18
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 290 MMBtu $ 3,454 $ 11.91 /MMBtu

TOTAL ENERGY

 290 MMBtu $ 3,454 -
15 view
details		 CHANGE RATE SCHEDULES OR OTHER CHANGES IN UTILITY SERVICE 2.8114 N $ 37,915 $ 8,751 4.33
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Electricity Fees

 - $ 8,751 -

TOTAL ENERGY

 0 MMBtu $ 8,751 -