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

Industrial Assessment Centers

Assessment #UD0824


Assessment Year 2010
SIC 3321
SIC Description Gray And Ductile Iron Foundries
NAICS 331511
NAICS Description Iron Foundries
Principal Product gray and ductile castings
Sales $ 52,292,000
# of Employees 300
Plant Area (Sq.Ft.) 463,000
Annual Production 29,974 Tons
Production Hrs. Annual 2,640
Location (State) OH
Yearly Energy Cost $ 2,955,922

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 40,287,654 kWh $ 1,601,455 $ 0.040 /kWh

- Demand Charge

 11,722 kW $ 900,818 $ 76.85 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 46,221 MMBtu $ 453,649 $ 9.81 /MMBtu

TOTAL ENERGY

 459,169 MMBtu $ 2,955,922 $ 6.44 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 11,164,282 kWh
0 kWh		 $ 1,756,383
$ 0		 109.67 %
0.00 %		 $ 0.040 /kWh

- Demand Charge

 328 kW
0 kW		 $ 36,941
$ 0		 4.10 %
0.00 %		 $ 76.85 /kW

- Electricity Fees

 - $ 48,864
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 7,544 MMBtu
0 MMBtu		 $ 74,013
$ 0		 16.32 %
0.00 %		 $ 9.81 /MMBtu

TOTAL ENERGY

 121,977 MMBtu
0 MMBtu		 $ 1,916,201
$ 0		 64.83 %
0.00 %		 $ 6.44 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 USE FOSSIL FUEL POWERED GENERATOR DURING PEAK DEMAND PERIODS 2.3192 N $ 143,000 $ 48,864 2.93
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Electricity Fees

 - $ 48,864 -

TOTAL ENERGY

 0 MMBtu $ 48,864 -
02 view
details		 INSTALL WIND POWERED ELECTRIC GENERATOR 2.9121 N $ 3,000,000 $ 1,443,350 2.08
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 5,281,037 kWh $ 1,443,350 $ 0.040 /kWh

TOTAL ENERGY

 54,131 MMBtu $ 1,443,350 -
03 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 N $ 15,238 $ 8,706 1.75
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 136,322 kWh $ 7,239 $ 0.040 /kWh

- Demand Charge

 24 kW $ 2,349 $ 76.85 /kW

TOTAL ENERGY

 1,397 MMBtu $ 9,588 -

Personnel Changes

 - $ -882 -

TOTAL PRODUCTON

 - $ -882 -
04 view
details		 UTILIZE DAYLIGHT WHENEVER POSSIBLE IN LIEU OF ARTIFICIAL LIGHT 2.7121 N $ 10,195 $ 8,478 1.20
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 159,662 kWh $ 8,478 $ 0.040 /kWh

TOTAL ENERGY

 1,637 MMBtu $ 8,478 -
05 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 N $ 6,380 $ 11,762 0.54
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 98,963 kWh $ 6,154 $ 0.040 /kWh

- Demand Charge

 9 kW $ 5,255 $ 76.85 /kW

TOTAL ENERGY

 1,014 MMBtu $ 11,409 -

Personnel Changes

 - $ 353 -

TOTAL PRODUCTON

 - $ 353 -
06 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 N $ 4,640 $ 4,468 1.04
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 70,182 kWh $ 3,727 $ 0.040 /kWh

- Demand Charge

 7 kW $ 654 $ 76.85 /kW

TOTAL ENERGY

 719 MMBtu $ 4,381 -

Personnel Changes

 - $ 87 -

TOTAL PRODUCTON

 - $ 87 -
07 view
details		 UTILIZE ENERGY-EFFICIENT BELTS AND OTHER IMPROVED MECHANISMS 2.4111 N $ 20 $ 2,897 0.01
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 31,944 kWh $ 1,696 $ 0.040 /kWh

- Demand Charge

 12 kW $ 1,201 $ 76.85 /kW

TOTAL ENERGY

 327 MMBtu $ 2,897 -
08 view
details		 UPGRADE CONTROLS ON COMPRESSORS 2.4224 N $ 20,000 $ 81,554 0.25
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 1,324,210 kWh $ 70,317 $ 0.040 /kWh

- Demand Charge

 113 kW $ 11,237 $ 76.85 /kW

TOTAL ENERGY

 13,573 MMBtu $ 81,554 -
09 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 N $ 16,000 $ 49,948 0.32
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 710,208 kWh $ 37,712 $ 0.040 /kWh

- Demand Charge

 123 kW $ 12,236 $ 76.85 /kW

TOTAL ENERGY

 7,280 MMBtu $ 49,948 -
10 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 N $ 1,500 $ 14,595 0.10
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 201,600 kWh $ 10,705 $ 0.040 /kWh

- Demand Charge

 39 kW $ 3,890 $ 76.85 /kW

TOTAL ENERGY

 2,066 MMBtu $ 14,595 -
11 view
details		 ELIMINATE OR REDUCE COMPRESSED AIR USED FOR COOLING, AGITATING LIQUIDS, MOVING PRODUCT, OR DRYING 2.4232 N $ 2,000 $ 14,160 0.14
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 266,667 kWh $ 14,160 $ 0.040 /kWh

TOTAL ENERGY

 2,733 MMBtu $ 14,160 -
12 view
details		 USE OR REPLACE WITH ENERGY EFFICIENT SUBSTITUTES 2.4322 N $ 540 $ 486 1.11
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 6,912 kWh $ 367 $ 0.040 /kWh

- Demand Charge

 1 kW $ 119 $ 76.85 /kW

TOTAL ENERGY

 71 MMBtu $ 486 -
13 view
details		 COVER OPEN TANKS 2.2514 N $ 1,600 $ 80,740 0.02
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 1,523,405 kWh $ 80,740 $ 0.040 /kWh

TOTAL ENERGY

 15,615 MMBtu $ 80,740 -
14 view
details		 INSULATE BARE EQUIPMENT 2.2511 N $ 5,152 $ 61,285 0.08
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 1,156,320 kWh $ 61,285 $ 0.040 /kWh

TOTAL ENERGY

 11,852 MMBtu $ 61,285 -
15 view
details		 REPLACE HEAT TREATING OVEN WITH MORE EFFICIENT UNIT 2.2314 N $ 1,243,001 $ 43,001 28.91
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 4,383 MMBtu $ 43,001 $ 9.81 /MMBtu

TOTAL ENERGY

 4,383 MMBtu $ 43,001 -
16 view
details		 INSTALL AUTOMATIC STACK DAMPER 2.1123 N $ 500 $ 22,399 0.02
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 2,283 MMBtu $ 22,399 $ 9.81 /MMBtu

TOTAL ENERGY

 2,283 MMBtu $ 22,399 -
17 view
details		 COVER OPEN TANKS 2.2514 N $ 17,226 $ 8,613 2.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 878 MMBtu $ 8,613 $ 9.81 /MMBtu

TOTAL ENERGY

 878 MMBtu $ 8,613 -
18 view
details		 USE HIGHEST TEMPERATURE FOR CHILLING OR COLD STORAGE 2.2694 N $ 36,212 $ 18,106 2.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Water Consumption

 - $ 18,106 -

TOTAL PRODUCTON

 - $ 18,106 -
19 view
details		 USE ADJUSTABLE FREQUENCY DRIVE TO REPLACE THROTTLING SYSTEM 2.4143 N $ 11,700 $ 6,081 1.92
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 114,514 kWh $ 6,081 $ 0.040 /kWh

TOTAL ENERGY

 1,174 MMBtu $ 6,081 -
20 view
details		 USE ADJUSTABLE FREQUENCY DRIVE TO REPLACE MECHANICAL DRIVE 2.4144 N $ 11,000 $ 4,372 2.52
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 82,336 kWh $ 4,372 $ 0.040 /kWh

TOTAL ENERGY

 844 MMBtu $ 4,372 -