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

Industrial Assessment Centers

Assessment #UD0861


Assessment Year 2012
SIC 3325
SIC Description Steel Foundries, Nec
NAICS 331513
NAICS Description Steel Foundries (except Investment)
Principal Product Steel and iron casting
Sales $ 20,000,000
# of Employees 130
Plant Area (Sq.Ft.) 278,000
Annual Production 7,500,000 Pounds
Production Hrs. Annual 7,488
Location (State) OH
Yearly Energy Cost $ 778,426

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 9,551,154 kWh $ 358,219 $ 0.038 /kWh

- Demand Charge

 28,188 kW $ 253,185 $ 8.98 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 32,502 MMBtu $ 167,022 $ 5.14 /MMBtu

TOTAL ENERGY

 130,402 MMBtu $ 778,426 $ 5.97 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 676,660 kWh
658,804 kWh		 $ 30,671
$ 28,209		 8.56 %
7.87 %		 $ 0.038 /kWh

- Demand Charge

 2,226 kW
2,250 kW		 $ 20,386
$ 21,037		 8.05 %
8.31 %		 $ 8.98 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 4,757 MMBtu
1,611 MMBtu		 $ 24,447
$ 8,278		 14.64 %
4.96 %		 $ 5.14 /MMBtu

TOTAL ENERGY

 11,693 MMBtu
8,364 MMBtu		 $ 75,504
$ 57,524		 9.70 %
7.39 %		 $ 5.97 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 RESCHEDULE PLANT OPERATIONS OR REDUCE LOAD TO AVOID PEAKS 2.3131 I $ 0 $ 15,708 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Demand Charge

 1,680 kW $ 15,708 $ 8.98 /kW

TOTAL ENERGY

 0 MMBtu $ 15,708 -
02 view
details		 USE COOLING TOWER WATER INSTEAD OF REFRIGERATION 2.2612 N $ 10,000 $ 8,039 1.24
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 -34,913 kWh $ -1,361 $ 0.038 /kWh

- Demand Charge

 -108 kW $ -1,046 $ 8.98 /kW

TOTAL ENERGY

 -358 MMBtu $ -2,407 -

Water Disposal

 2,520,760 Gal $ 10,446 $ 0 /Gal

TOTAL WASTE

 - $ 10,446 -
03 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 N $ 3,496 $ 4,507 0.78
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 52,769 kWh $ 3,823 $ 0.038 /kWh

- Demand Charge

 84 kW $ 395 $ 8.98 /kW

TOTAL ENERGY

 541 MMBtu $ 4,218 -

Personnel Changes

 - $ 289 -

TOTAL PRODUCTON

 - $ 289 -
04 view
details		 TURN OFF EQUIPMENT WHEN NOT IN USE 2.6218 I $ 0 $ 3,025 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 77,584 kWh $ 3,025 $ 0.038 /kWh

TOTAL ENERGY

 795 MMBtu $ 3,025 -
05 view
details		 DEVELOP A REPAIR/REPLACE POLICY 2.4151 I $ 3,440 $ 1,371 2.51
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 25,412 kWh $ 991 $ 0.038 /kWh

- Demand Charge

 41 kW $ 380 $ 8.98 /kW

TOTAL ENERGY

 260 MMBtu $ 1,371 -
06 view
details		 UTILIZE ENERGY-EFFICIENT BELTS AND OTHER IMPROVED MECHANISMS 2.4111 I $ 0 $ 1,167 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 21,624 kWh $ 843 $ 0.038 /kWh

- Demand Charge

 35 kW $ 324 $ 8.98 /kW

TOTAL ENERGY

 222 MMBtu $ 1,167 -
07 view
details		 UPGRADE CONTROLS ON COMPRESSORS 2.4224 I $ 2,000 $ 14,934 0.13
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 273,600 kWh $ 10,670 $ 0.038 /kWh

- Demand Charge

 456 kW $ 4,264 $ 8.98 /kW

TOTAL ENERGY

 2,804 MMBtu $ 14,934 -
08 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 1,000 $ 701 1.43
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 24,112 kWh $ 940 $ 0.038 /kWh

- Demand Charge

 38 kW $ 361 $ 8.98 /kW

TOTAL ENERGY

 247 MMBtu $ 1,301 -

Personnel Changes

 - $ -600 -

TOTAL PRODUCTON

 - $ -600 -
09 view
details		 COVER OPEN TANKS 2.2514 I $ 0 $ 6,896 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,342 MMBtu $ 6,896 $ 5.14 /MMBtu

TOTAL ENERGY

 1,342 MMBtu $ 6,896 -
10 view
details		 COVER OPEN TANKS 2.2514 I $ 0 $ 6,786 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 109,457 kWh $ 6,786 $ 0.038 /kWh

TOTAL ENERGY

 1,122 MMBtu $ 6,786 -
11 view
details		 USE WASTE HEAT FROM HOT FLUE GASES TO PREHEAT COMBUSTION AIR 2.2411 N $ 11,000 $ 6,234 1.76
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,213 MMBtu $ 6,234 $ 5.14 /MMBtu

TOTAL ENERGY

 1,213 MMBtu $ 6,234 -
12 view
details		 USE WASTE HEAT FROM HOT FLUE GASES TO PREHEAT COMBUSTION AIR 2.2411 N $ 10,000 $ 5,453 1.83
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,061 MMBtu $ 5,453 $ 5.14 /MMBtu

TOTAL ENERGY

 1,061 MMBtu $ 5,453 -
13 view
details		 COVER OPEN TANKS 2.2514 I $ 0 $ 4,954 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 127,015 kWh $ 4,954 $ 0.038 /kWh

TOTAL ENERGY

 1,302 MMBtu $ 4,954 -
14 view
details		 USE WASTE HEAT FROM HOT FLUE GASES TO PREHEAT COMBUSTION AIR 2.2411 N $ 9,000 $ 4,482 2.01
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 872 MMBtu $ 4,482 $ 5.14 /MMBtu

TOTAL ENERGY

 872 MMBtu $ 4,482 -
15 view
details		 ISOLATE HOT OR COLD EQUIPMENT 2.2522 I $ 1,500 $ 1,382 1.09
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 269 MMBtu $ 1,382 $ 5.14 /MMBtu

TOTAL ENERGY

 269 MMBtu $ 1,382 -