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

Industrial Assessment Centers

Assessment #UD0732


Assessment Year 2006
SIC 3315
SIC Description Steel Wire And Related Products
NAICS 331512
NAICS Description Steel Investment Foundries
Principal Product Steel wire
Sales $ 26,000,000
# of Employees 55
Plant Area (Sq.Ft.) 300,000
Annual Production 38,000,000 Tons
Production Hrs. Annual 8,400
Location (State) OH
Yearly Energy Cost $ 1,101,362

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 11,155,200 kWh $ 245,333 $ 0.022 /kWh

- Demand Charge

 26,364 kW $ 282,337 $ 10.71 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 78,240 MMBtu $ 573,692 $ 7.33 /MMBtu

TOTAL ENERGY

 192,581 MMBtu $ 1,101,362 $ 5.72 /MMBtu

Water Disposal

 1,612,904 Gal $ 12,007 $ 0 /Gal

Recommended Reduction in Usage & Costs

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

Electricity

 1,401,040 kWh
433,440 kWh		 $ 43,687
$ 17,348		 17.81 %
7.07 %		 $ 0.022 /kWh

- Demand Charge

 1,540 kW
172 kW		 $ 16,365
$ 1,851		 5.80 %
0.66 %		 $ 10.71 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 15,781 MMBtu
5,994 MMBtu		 $ 122,134
$ 46,393		 21.29 %
8.09 %		 $ 7.33 /MMBtu

TOTAL ENERGY

 30,142 MMBtu
10,437 MMBtu		 $ 182,186
$ 65,592		 16.54 %
5.96 %		 $ 5.72 /MMBtu

Water Disposal

 204,231 Gal
0 Gal		 $ 1,525
$ 0		 12.70 %
0.00 %		 $ 0 /Gal

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 N $ 99,815 $ 42,044 2.37
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 934,000 kWh $ 25,600 $ 0.022 /kWh

- Demand Charge

 1,320 kW $ 14,000 $ 10.71 /kW

TOTAL ENERGY

 9,574 MMBtu $ 39,600 -

Administrative Changes

 - $ 2,444 -

TOTAL PRODUCTON

 - $ 2,444 -
02 view
details		 ANALYZE FLUE GAS FOR PROPER AIR/FUEL RATIO 2.1233 N $ 0 $ 30,349 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 3,921 MMBtu $ 30,349 $ 7.33 /MMBtu

TOTAL ENERGY

 3,921 MMBtu $ 30,349 -
03 view
details		 ANALYZE FLUE GAS FOR PROPER AIR/FUEL RATIO 2.1233 I $ 2,000 $ 22,274 0.09
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 2,878 MMBtu $ 22,274 $ 7.33 /MMBtu

TOTAL ENERGY

 2,878 MMBtu $ 22,274 -
04 view
details		 COVER OPEN TANKS WITH FLOATING INSULATION 2.2513 N $ 14,623 $ 23,047 0.63
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 2,781 MMBtu $ 21,522 $ 7.33 /MMBtu

TOTAL ENERGY

 2,781 MMBtu $ 21,522 -

Water Disposal

 204,231 Gal $ 1,525 $ 0 /Gal

TOTAL WASTE

 - $ 1,525 -
05 view
details		 USE FLUE GAS HEAT TO PREHEAT BOILER FEEDWATER 2.2412 N $ 20,000 $ 18,913 1.06
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 2,444 MMBtu $ 18,913 $ 7.33 /MMBtu

TOTAL ENERGY

 2,444 MMBtu $ 18,913 -
06 view
details		 MAKE A PRACTICE OF TURNING OFF LIGHTS WHEN NOT NEEDED 2.7124 I $ 0 $ 14,687 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 312,480 kWh $ 14,687 $ 0.022 /kWh

TOTAL ENERGY

 3,203 MMBtu $ 14,687 -
07 view
details		 ANALYZE FLUE GAS FOR PROPER AIR/FUEL RATIO 2.1233 I $ 0 $ 13,718 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,772 MMBtu $ 13,718 $ 7.33 /MMBtu

TOTAL ENERGY

 1,772 MMBtu $ 13,718 -
08 view
details		 IMPROVE COMBUSTION CONTROL CAPABILITY 2.1116 I $ 0 $ 9,263 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,197 MMBtu $ 9,263 $ 7.33 /MMBtu

TOTAL ENERGY

 1,197 MMBtu $ 9,263 -
09 view
details		 INSULATE BARE EQUIPMENT 2.2511 N $ 418 $ 3,480 0.12
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 450 MMBtu $ 3,480 $ 7.33 /MMBtu

TOTAL ENERGY

 450 MMBtu $ 3,480 -
10 view
details		 UPGRADE CONTROLS ON COMPRESSORS 2.4224 I $ 0 $ 2,569 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 68,880 kWh $ 1,515 $ 0.022 /kWh

- Demand Charge

 98 kW $ 1,054 $ 10.71 /kW

TOTAL ENERGY

 706 MMBtu $ 2,569 -
11 view
details		 INSULATE BARE EQUIPMENT 2.2511 N $ 910 $ 1,477 0.62
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 191 MMBtu $ 1,477 $ 7.33 /MMBtu

TOTAL ENERGY

 191 MMBtu $ 1,477 -
12 view
details		 UTILIZE ENERGY-EFFICIENT BELTS AND OTHER IMPROVED MECHANISMS 2.4111 N $ 0 $ 1,253 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 33,600 kWh $ 739 $ 0.022 /kWh

- Demand Charge

 48 kW $ 514 $ 10.71 /kW

TOTAL ENERGY

 344 MMBtu $ 1,253 -
13 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 I $ 0 $ 1,160 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 31,080 kWh $ 684 $ 0.022 /kWh

- Demand Charge

 44 kW $ 476 $ 10.71 /kW

TOTAL ENERGY

 319 MMBtu $ 1,160 -
14 view
details		 REPAIR AND ELIMINATE STEAM LEAKS 2.2135 I $ 600 $ 1,138 0.53
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 147 MMBtu $ 1,138 $ 7.33 /MMBtu

TOTAL ENERGY

 147 MMBtu $ 1,138 -
15 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 720 $ 783 0.92
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 21,000 kWh $ 462 $ 0.022 /kWh

- Demand Charge

 30 kW $ 321 $ 10.71 /kW

TOTAL ENERGY

 215 MMBtu $ 783 -