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

Industrial Assessment Centers

Assessment #UD0664


Assessment Year 2003
SIC 3325
SIC Description Steel Foundries, Nec
NAICS 331513
NAICS Description Steel Foundries (except Investment)
Principal Product Stainless steel / nickel base pump & valves castings
Sales $ 15,000,000
# of Employees 114
Plant Area (Sq.Ft.) 240,000
Annual Production 3,300 Tons
Production Hrs. Annual 5,250
Location (State) OH
Yearly Energy Cost $ 1,718,943

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 16,492,880 kWh $ 434,028 $ 0.026 /kWh

- Demand Charge

 52,104 kW $ 665,435 $ 12.77 /kW

- Electricity Fees

 - $ 7,750 -

Natural Gas

 109,055 MMBtu $ 611,730 $ 5.61 /MMBtu

TOTAL ENERGY

 278,107 MMBtu $ 1,718,943 $ 6.18 /MMBtu

Water Disposal

 30,102,048 Gal $ 87,990 $ 0 /Gal

Recommended Reduction in Usage & Costs

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

Electricity

 1,007,017 kWh
63,142 kWh		 $ 26,234
$ 1,660		 6.04 %
0.38 %		 $ 0.026 /kWh

- Demand Charge

 787 kW
13 kW		 $ 120,962
$ 1,987		 18.18 %
0.30 %		 $ 12.77 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 19,476 MMBtu
0 MMBtu		 $ 111,786
$ 0		 18.27 %
0.00 %		 $ 5.61 /MMBtu

TOTAL ENERGY

 29,798 MMBtu
648 MMBtu		 $ 258,982
$ 3,647		 15.07 %
0.21 %		 $ 6.18 /MMBtu

Water Disposal

 0 Gal
0 Gal		 $ 0
$ 0		 0.00 %
0.00 %		 $ 0 /Gal

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 USE DEMAND CONTROLLER OR LOAD SHEDDER 2.3191 N $ 1,000 $ 115,000 0.01
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Demand Charge

 748 kW $ 115,000 $ 12.77 /kW

TOTAL ENERGY

 0 MMBtu $ 115,000 -
02 view
details		 RECYCLE AIR FOR HEATING, VENTILATION AND AIR CONDITIONING 2.7313 N $ 144,000 $ 61,800 2.33
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 12,491 MMBtu $ 72,600 $ 5.61 /MMBtu

TOTAL ENERGY

 12,491 MMBtu $ 72,600 -

Ancillary Material Cost

 - $ -10,800 -

TOTAL PRODUCTON

 - $ -10,800 -
03 view
details		 USE CLOSED CYCLE PROCESS TO MINIMIZE WASTE WATER PRODUCTION 3.4111 I $ 35,000 $ 61,795 0.57
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 -75,608 kWh $ -1,988 $ 0.026 /kWh

- Demand Charge

 -9 kW $ -1,433 $ 12.77 /kW

TOTAL ENERGY

 -775 MMBtu $ -3,421 -

Water Consumption

 - $ 65,216 -

TOTAL PRODUCTON

 - $ 65,216 -
04 view
details		 USE OR REPLACE WITH ENERGY EFFICIENT SUBSTITUTES 2.4322 P $ 28,500 $ 37,413 0.76
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 6,669 MMBtu $ 37,413 $ 5.61 /MMBtu

TOTAL ENERGY

 6,669 MMBtu $ 37,413 -
05 view
details		 USE DEMAND CONTROLLER OR LOAD SHEDDER 2.3191 N $ 2,600 $ 16,536 0.16
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 636,000 kWh $ 16,536 $ 0.026 /kWh

TOTAL ENERGY

 6,519 MMBtu $ 16,536 -
06 view
details		 SHUT OFF COOLING WATER WHEN NOT REQUIRED 2.6216 I $ 800 $ 6,785 0.12
Energy Sources Yearly Reduction Yearly Savings Unit Price

Water Consumption

 - $ 6,785 -

TOTAL PRODUCTON

 - $ 6,785 -
07 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 12,830 $ 4,070 3.15
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 78,000 kWh $ 2,050 $ 0.026 /kWh

- Demand Charge

 13 kW $ 2,020 $ 12.77 /kW

TOTAL ENERGY

 800 MMBtu $ 4,070 -
08 view
details		 USE OR REPLACE WITH ENERGY EFFICIENT SUBSTITUTES 2.4322 N $ 111 $ 3,884 0.03
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 149,400 kWh $ 3,884 $ 0.026 /kWh

TOTAL ENERGY

 1,531 MMBtu $ 3,884 -
09 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 N $ 5,820 $ 3,630 1.60
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 69,600 kWh $ 1,830 $ 0.026 /kWh

- Demand Charge

 12 kW $ 1,800 $ 12.77 /kW

TOTAL ENERGY

 713 MMBtu $ 3,630 -
10 view
details		 UTILIZE ENERGY-EFFICIENT BELTS AND OTHER IMPROVED MECHANISMS 2.4111 N $ 378 $ 3,280 0.12
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 42,000 kWh $ 1,105 $ 0.026 /kWh

- Demand Charge

 14 kW $ 2,175 $ 12.77 /kW

TOTAL ENERGY

 431 MMBtu $ 3,280 -
11 view
details		 DISCONNECT BALLASTS 2.7122 I $ 250 $ 2,820 0.09
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 54,000 kWh $ 1,420 $ 0.026 /kWh

- Demand Charge

 9 kW $ 1,400 $ 12.77 /kW

TOTAL ENERGY

 554 MMBtu $ 2,820 -
12 view
details		 INSULATE BARE EQUIPMENT 2.2511 N $ 1,800 $ 1,414 1.27
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 252 MMBtu $ 1,414 $ 5.61 /MMBtu

TOTAL ENERGY

 252 MMBtu $ 1,414 -
13 view
details		 TURN OFF EQUIPMENT WHEN NOT IN USE 2.6218 N $ 0 $ 1,219 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 46,875 kWh $ 1,219 $ 0.026 /kWh

TOTAL ENERGY

 480 MMBtu $ 1,219 -
14 view
details		 IMPROVE COMBUSTION CONTROL CAPABILITY 2.1116 N $ 25 $ 247 0.10
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 44 MMBtu $ 247 $ 5.61 /MMBtu

TOTAL ENERGY

 44 MMBtu $ 247 -
15 view
details		 TURN OFF EQUIPMENT WHEN NOT IN USE 2.6218 I $ 0 $ 178 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 6,750 kWh $ 178 $ 0.026 /kWh

TOTAL ENERGY

 69 MMBtu $ 178 -
16 view
details		 MINIMIZE NON-ESSENTIAL MATERIAL IN HEAT TREATMENT PROCESS 2.2312 N $ 0 $ 112 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 20 MMBtu $ 112 $ 5.61 /MMBtu

TOTAL ENERGY

 20 MMBtu $ 112 -