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

Industrial Assessment Centers

Assessment #TN0586


Assessment Year 1996
SIC 3714
SIC Description Motor Vehicle Parts And Accessories
NAICS
NAICS Description
Principal Product Automobile shock absorbers and suspension struts
Sales $ 150,000,000
# of Employees 825
Plant Area (Sq.Ft.) 500,000
Annual Production 15,000,000 Pieces
Production Hrs. Annual 7,200
Location (State) TN
Yearly Energy Cost $ 2,541,770

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 42,452,521 kWh $ 1,654,761 $ 0.039 /kWh

- Demand Charge

 93,529 kW $ 358,513 $ 3.83 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 131,819 MMBtu $ 528,496 $ 4.01 /MMBtu

TOTAL ENERGY

 566,957 MMBtu $ 2,541,770 $ 4.48 /MMBtu

Water Disposal

 174,980,000 Gal $ 210,187 $ 0 /Gal

Other Liquid (non-haz)

 90,140 Gal $ 44,500 $ 0 /Gal

Other Liquid (haz)

 1,400 Gal $ 58,275 $ 0 /Gal

Solid Waste (non-haz)

 1,286,480 lbs $ -4,116 $ 0 /lbs

Solid Waste (haz)

 328,000 lbs $ 63,400 $ 0 /lbs

Recommended Reduction in Usage & Costs

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

Electricity

 1,360,785 kWh
947,831 kWh		 $ 34,020
$ 23,700		 2.06 %
1.43 %		 $ 0.039 /kWh

- Demand Charge

 1,668 kW
1,560 kW		 $ 16,445
$ 15,380		 4.59 %
4.29 %		 $ 3.83 /kW

- Electricity Fees

 - $ 25,125
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 248 MMBtu
0 MMBtu		 $ 990
$ 0		 0.19 %
0.00 %		 $ 4.01 /MMBtu

TOTAL ENERGY

 14,195 MMBtu
9,715 MMBtu		 $ 76,580
$ 39,080		 3.01 %
1.54 %		 $ 4.48 /MMBtu

Water Disposal

 13,968,000 Gal
0 Gal		 $ 16,875
$ 0		 8.03 %
0.00 %		 $ 0 /Gal

Other Liquid (non-haz)

 72,080 Gal
0 Gal		 $ 35,450
$ 0		 79.66 %
0.00 %		 $ 0 /Gal

Other Liquid (haz)

 700 Gal
0 Gal		 $ 29,140
$ 0		 50.00 %
0.00 %		 $ 0 /Gal

Solid Waste (non-haz)

 367,500 lbs
367,500 lbs		 $ 2,740
$ 2,740		 -66.57 %
-66.57 %		 $ 0 /lbs

Solid Waste (haz)

 104,960 lbs
0 lbs		 $ 20,290
$ 0		 32.00 %
0.00 %		 $ 0 /lbs

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 REDUCE SOLUTION DRAG-OUT TO PREVENT SOLUTION LOSS 3.1244 N $ 15,300 $ 50,410 0.30
Energy Sources Yearly Reduction Yearly Savings Unit Price

Other Liquid (non-haz)

 40 Gal $ 250 $ 0 /Gal

Other Liquid (haz)

 700 Gal $ 29,140 $ 0 /Gal

Solid Waste (haz)

 104,960 lbs $ 20,290 $ 0 /lbs

TOTAL WASTE

 - $ 49,680 -

Primary Raw Material

 - $ 730 -

TOTAL PRODUCTON

 - $ 730 -
02 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 7,880 $ 39,080 0.20
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 947,831 kWh $ 23,700 $ 0.039 /kWh

- Demand Charge

 1,560 kW $ 15,380 $ 3.83 /kW

TOTAL ENERGY

 9,715 MMBtu $ 39,080 -
03 view
details		 USE EVAPORATION TO CONCENTRATE MATERIAL 3.3131 N $ 30,600 $ 32,200 0.95
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 -750 MMBtu $ -3,000 $ 4.01 /MMBtu

TOTAL ENERGY

 -750 MMBtu $ -3,000 -

Other Liquid (non-haz)

 72,040 Gal $ 35,200 $ 0 /Gal

TOTAL WASTE

 - $ 35,200 -
04 view
details		 TREAT AND REUSE RINSE WATERS 3.4113 N $ 66,740 $ 29,935 2.23
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 -53,048 kWh $ -1,330 $ 0.039 /kWh

- Demand Charge

 -252 kW $ -2,485 $ 3.83 /kW

TOTAL ENERGY

 -544 MMBtu $ -3,815 -

Water Disposal

 13,968,000 Gal $ 16,875 $ 0 /Gal

TOTAL WASTE

 - $ 16,875 -

Water Consumption

 - $ 16,875 -

TOTAL PRODUCTON

 - $ 16,875 -
05 view
details		 USE POWER FACTOR CONTROLLERS 2.3211 N $ 60,800 $ 25,125 2.42
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Electricity Fees

 - $ 25,125 -

TOTAL ENERGY

 0 MMBtu $ 25,125 -
06 view
details		 UTILIZE ENERGY-EFFICIENT BELTS AND OTHER IMPROVED MECHANISMS 2.4111 N $ 7,350 $ 7,800 0.94
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 169,988 kWh $ 4,250 $ 0.039 /kWh

- Demand Charge

 360 kW $ 3,550 $ 3.83 /kW

TOTAL ENERGY

 1,742 MMBtu $ 7,800 -
07 view
details		 UPGRADE CONTROLS ON COMPRESSORS 2.4224 N $ 29,600 $ 7,400 4.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 296,014 kWh $ 7,400 $ 0.039 /kWh

TOTAL ENERGY

 3,034 MMBtu $ 7,400 -
08 view
details		 INSULATE BARE EQUIPMENT 2.2511 N $ 4,400 $ 3,650 1.21
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 912 MMBtu $ 3,650 $ 4.01 /MMBtu

TOTAL ENERGY

 912 MMBtu $ 3,650 -
09 view
details		 INCREASE AMOUNT OF WASTE RECOVERED FOR RESALE 3.5313 I $ 0 $ 4,410 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Solid Waste (non-haz)

 367,500 lbs $ 2,740 $ 0 /lbs

TOTAL WASTE

 - $ 2,740 -

Administrative Changes

 - $ 1,670 -

TOTAL PRODUCTON

 - $ 1,670 -
10 view
details		 INSTALL / REPAIR INSULATION ON CONDENSATE LINES 2.2122 N $ 260 $ 340 0.76
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 86 MMBtu $ 340 $ 4.01 /MMBtu

TOTAL ENERGY

 86 MMBtu $ 340 -