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

Industrial Technologies Program

Industrial Assessment Centers

Assessment #WI0353


Assessment Year 1999
SIC 3366
SIC Description Copper Foundries
NAICS
NAICS Description
Principal Product Aluminum, Bronze, and Copper Alloys
Sales $ 40,000,000
# of Employees 254
Plant Area (Sq.Ft.) 550,190
Annual Production 14,000,000 Pounds
Production Hrs. Annual 6,000
Location (State) WI
Yearly Energy Cost $ 1,246,757

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 13,952,228 kWh $ 363,578 $ 0.026 /kWh

- Demand Charge

 43,108 kW $ 392,651 $ 9.11 /kW

- Electricity Fees

 - $ 73,590 -

Natural Gas

 114,854 MMBtu $ 416,938 $ 3.63 /MMBtu

TOTAL ENERGY

 257,864 MMBtu $ 1,246,757 $ 4.83 /MMBtu

Water Disposal

 115,611,000 Gal $ 98,683 $ 0 /Gal

Other Liquid (haz)

 36,000 Gal $ 18,900 $ 0 /Gal

Solid Waste (non-haz)

 1,440,000 lbs $ -83,400 $ 0 /lbs

Recommended Reduction in Usage & Costs

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

Electricity

 65,651 kWh
38,394 kWh		 $ 1,806
$ 1,055		 0.50 %
0.29 %		 $ 0.026 /kWh

- Demand Charge

 595 kW
546 kW		 $ 5,757
$ 5,286		 1.47 %
1.35 %		 $ 9.11 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 5,593 MMBtu
0 MMBtu		 $ 20,305
$ 0		 4.87 %
0.00 %		 $ 3.63 /MMBtu

TOTAL ENERGY

 6,266 MMBtu
394 MMBtu		 $ 27,868
$ 6,341		 2.24 %
0.51 %		 $ 4.83 /MMBtu

Water Disposal

 10,404,990 Gal
10,404,990 Gal		 $ 7,137
$ 7,137		 7.23 %
7.23 %		 $ 0 /Gal

Other Liquid (haz)

 33,120 Gal
0 Gal		 $ 17,388
$ 0		 92.00 %
0.00 %		 $ 0 /Gal

Solid Waste (non-haz)

 0 lbs
0 lbs		 $ 0
$ 0		 0.00 %
0.00 %		 $ 0 /lbs

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 PAY BILLS ON TIME TO AVOID LATE FEES 4.8210 N $ 0 $ 26,146 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Administrative Changes

 - $ 26,146 -

TOTAL PRODUCTON

 - $ 26,146 -
02 view
details		 REPLACE OBSOLETE BURNERS WITH MORE EFFICIENT ONES 2.1221 N $ 72,000 $ 21,494 3.35
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 5,921 MMBtu $ 21,494 $ 3.63 /MMBtu

TOTAL ENERGY

 5,921 MMBtu $ 21,494 -
03 view
details		 USE EVAPORATION TO CONCENTRATE MATERIAL 3.3131 N $ 16,000 $ 13,199 1.21
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 -328 MMBtu $ -1,189 $ 3.63 /MMBtu

TOTAL ENERGY

 -328 MMBtu $ -1,189 -

Other Liquid (haz)

 33,120 Gal $ 17,388 $ 0 /Gal

TOTAL WASTE

 - $ 17,388 -

Personnel Changes

 - $ -3,000 -

TOTAL PRODUCTON

 - $ -3,000 -
04 view
details		 REPLACE CITY WATER WITH RECYCLED WATER VIA COOLING TOWER 3.4114 I $ 22,000 $ 6,159 3.57
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 -20,809 kWh $ -575 $ 0.026 /kWh

- Demand Charge

 -42 kW $ -403 $ 9.11 /kW

TOTAL ENERGY

 -213 MMBtu $ -978 -

Water Disposal

 10,404,990 Gal $ 7,137 $ 0 /Gal

TOTAL WASTE

 - $ 7,137 -
05 view
details		 RESCHEDULE PLANT OPERATIONS OR REDUCE LOAD TO AVOID PEAKS 2.3131 I $ 0 $ 4,879 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Demand Charge

 504 kW $ 4,879 $ 9.11 /kW

TOTAL ENERGY

 0 MMBtu $ 4,879 -
06 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 I $ 640 $ 2,440 0.26
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 59,203 kWh $ 1,630 $ 0.026 /kWh

- Demand Charge

 84 kW $ 810 $ 9.11 /kW

TOTAL ENERGY

 607 MMBtu $ 2,440 -
07 view
details		 UTILIZE ENERGY-EFFICIENT BELTS AND OTHER IMPROVED MECHANISMS 2.4111 N $ 624 $ 785 0.79
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 16,706 kWh $ 462 $ 0.026 /kWh

- Demand Charge

 34 kW $ 323 $ 9.11 /kW

TOTAL ENERGY

 171 MMBtu $ 785 -
08 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 N $ 243 $ 437 0.56
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 10,551 kWh $ 289 $ 0.026 /kWh

- Demand Charge

 15 kW $ 148 $ 9.11 /kW

TOTAL ENERGY

 108 MMBtu $ 437 -