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

Industrial Technologies Program

Industrial Assessment Centers

Assessment #UD0580

Assessment Year	1999
SIC	3496
SIC Description	Misc. Fabricated Wire Products
NAICS
NAICS Description
Principal Product	Welding wire
Sales	$ 42,000,000
# of Employees	250
Plant Area (Sq.Ft.)	350,000
Annual Production	105,000,000 Pounds
Production Hrs. Annual	8,400
Location (State)	OH
Yearly Energy Cost	$ 1,292,733

Current Energy Usage & Costs

Energy Sources	Yearly Usage	Yearly Cost	Unit Price
Electricity	15,994,725 kWh	$ 798,797	$ 0.050 /kWh
- Demand Charge	32,316 kW	$ 368,402	$ 11.40 /kW
- Electricity Fees	-	$ 0	-
Natural Gas	29,089 MMBtu	$ 125,534	$ 4.32 /MMBtu
TOTAL ENERGY	193,035 MMBtu	$ 1,292,733	$ 6.70 /MMBtu

Recommended Reduction in Usage & Costs

Recommended Implemented

Energy Sources	Yearly Savings	Yearly Cost	% Saved	Unit Price
Electricity	10,831,477 kWh 667,350 kWh	$ 606,558 $ 37,374	75.93 % 4.68 %	$ 0.050 /kWh
- Demand Charge	15,351 kW 831 kW	$ 175,009 $ 9,481	47.50 % 2.57 %	$ 11.40 /kW
- Electricity Fees	-	$ 0 $ 0	0.00 % 0.00 %	-
Natural Gas	-141,402 MMBtu 0 MMBtu	$ -608,029 $ 0	-484.35 % 0.00 %	$ 4.32 /MMBtu
TOTAL ENERGY	43,935 MMBtu 6,841 MMBtu	$ 909,247 $ 46,855	70.34 % 3.62 %	$ 6.70 /MMBtu

Recommendations

AR #

Description

ARC Code

Status

Cost

Savings

Payback
(Years)

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details

USE WASTE HEAT WITH A CLOSED-CYCLE GAS TURBINE-GENERATOR SET TO COGENERATE ELECTRICITY AND HEAT

2.3417

$ 1,300,000

$ 862,392

1.51

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Electricity	10,164,127 kWh	$ 569,184	$ 0.050 /kWh
- Demand Charge	14,520 kW	$ 165,528	$ 11.40 /kW
Natural Gas	-141,402 MMBtu	$ -608,029	$ 4.32 /MMBtu
Other Energy	74,314 MMBtu	$ 735,709	$ 0.00 /MMBtu
TOTAL ENERGY	37,094 MMBtu	$ 862,392	-

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details

ADD/MODIFY EQUIPMENT TO IMPROVE DRYING PROCESS

4.1140

$ 400,000

$ 134,400

2.98

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Personnel Changes	-	$ 134,400	-
TOTAL PRODUCTON	-	$ 134,400	-

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details

RECOVER AND REUSE COOLING WATER

3.4115

$ 140,000

$ 52,000

2.69

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Water Disposal	28,350,000 Gal	$ 35,000	$ 0 /Gal
TOTAL WASTE	-	$ 35,000	-
Administrative Changes	-	$ 17,000	-
TOTAL PRODUCTON	-	$ 17,000	-

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details

MOVE PRODUCT USING MECHANICAL MEANS

4.4230

$ 10,000

$ 39,393

0.25

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Personnel Changes	-	$ 16,800	-
Primary Product	-	$ 22,593	-
TOTAL PRODUCTON	-	$ 39,393	-

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details

USE COUNTER CURRENT RINSING TO REDUCE WASTE WATER

3.4153

$ 3,500

$ 27,840

0.13

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Water Disposal	18,144,000 Gal	$ 27,840	$ 0 /Gal
TOTAL WASTE	-	$ 27,840	-

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details

ELIMINATE OR REDUCE COMPRESSED AIR USED FOR COOLING, AGITATING LIQUIDS, MOVING PRODUCT, OR DRYING

2.4232

$ 11,744

$ 27,804

0.42

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Electricity	412,954 kWh	$ 23,126	$ 0.050 /kWh
- Demand Charge	410 kW	$ 4,678	$ 11.40 /kW
TOTAL ENERGY	4,233 MMBtu	$ 27,804	-

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details

UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS

2.7142

$ 30,337

$ 19,051

1.59

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Electricity	254,396 kWh	$ 14,248	$ 0.050 /kWh
- Demand Charge	421 kW	$ 4,803	$ 11.40 /kW
TOTAL ENERGY	2,608 MMBtu	$ 19,051	-

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details

FILTER AND REUSE HYDRAULIC OIL

3.5111

$ 2,500

$ 1,713

1.46

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Other Liquid (haz)	675 Gal	$ 492	$ 0 /Gal
Solid Waste (haz)	0 lbs	$ -129	$ 0 /lbs
TOTAL WASTE	-	$ 363	-
Ancillary Material Cost	-	$ 1,350	-
TOTAL PRODUCTON	-	$ 1,350	-

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details

SWITCH TO A SOLVENT THAT CAN BE CLEANED AND RE-USED

3.8136

$ 0

$ 1,418

0.00

Energy Sources	Yearly Reduction	Yearly Savings	Unit Price
Other Liquid (non-haz)	-5 Gal	$ -400	$ 0 /Gal
Other Liquid (haz)	200 Gal	$ 1,448	$ 0 /Gal
TOTAL WASTE	-	$ 1,048	-
Ancillary Material Cost	-	$ 370	-
TOTAL PRODUCTON	-	$ 370	-