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

Industrial Assessment Centers

Assessment #WI0359


Assessment Year 1999
SIC 3823
SIC Description Process Control Instruments
NAICS
NAICS Description
Principal Product Boiler Controls
Sales $ 50,000,000
# of Employees 250
Plant Area (Sq.Ft.) 150,000
Annual Production 0 Not Available
Production Hrs. Annual 6,000
Location (State) IL
Yearly Energy Cost $ 315,545

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 2,940,211 kWh $ 122,367 $ 0.042 /kWh

- Demand Charge

 7,851 kW $ 98,119 $ 12.50 /kW

- Electricity Fees

 - $ 35,105 -

Natural Gas

 14,420 MMBtu $ 59,954 $ 4.16 /MMBtu

TOTAL ENERGY

 44,557 MMBtu $ 315,545 $ 7.08 /MMBtu

Water Disposal

 4,054,000 Gal $ 8,718 $ 0 /Gal

Other Liquid (non-haz)

 960 Gal $ 9,000 $ 0 /Gal

Other Liquid (haz)

 990 Gal $ 990 $ 0 /Gal

Solid Waste (non-haz)

 360,000 lbs $ 8,400 $ 0 /lbs

Solid Waste (haz)

 39,600 lbs $ 2,250 $ 0 /lbs

Gaseous Waste

 623 lbs $ 0 $ 0 /lbs

Recommended Reduction in Usage & Costs

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

Electricity

 272,274 kWh
60,082 kWh		 $ 12,373
$ 2,722		 10.11 %
2.22 %		 $ 0.042 /kWh

- Demand Charge

 1,139 kW
89 kW		 $ 17,962
$ 1,220		 18.31 %
1.24 %		 $ 12.50 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 -2,581 MMBtu
139 MMBtu		 $ -9,344
$ 580		 -15.59 %
0.97 %		 $ 4.16 /MMBtu

TOTAL ENERGY

 209 MMBtu
754 MMBtu		 $ 20,991
$ 4,522		 6.65 %
1.43 %		 $ 7.08 /MMBtu

Water Disposal

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

Other Liquid (non-haz)

 605 Gal
0 Gal		 $ 8,505
$ 0		 94.50 %
0.00 %		 $ 0 /Gal

Other Liquid (haz)

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

Solid Waste (non-haz)

 -203 lbs
0 lbs		 $ -359
$ 0		 -4.27 %
0.00 %		 $ 0 /lbs

Solid Waste (haz)

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

Gaseous Waste

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

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 DISTILL CONTAMINATED SOLVENTS FOR REUSE 3.8142 N $ 7,500 $ 6,185 1.21
Energy Sources Yearly Reduction Yearly Savings Unit Price

Other Liquid (non-haz)

 605 Gal $ 8,505 $ 0 /Gal

Solid Waste (non-haz)

 -203 lbs $ -359 $ 0 /lbs

TOTAL WASTE

 - $ 8,146 -

Personnel Changes

 - $ -726 -

Primary Raw Material

 - $ -1,235 -

TOTAL PRODUCTON

 - $ -1,961 -
02 view
details		 USE A FOSSIL FUEL ENGINE TO COGENERATE ELECTRICITY OR MOTIVE POWER; AND UTILIZE HEAT 2.3415 N $ 24,000 $ 5,455 4.40
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 212,192 kWh $ 9,651 $ 0.042 /kWh

- Demand Charge

 672 kW $ 9,186 $ 12.50 /kW

Natural Gas

 -3,217 MMBtu $ -13,382 $ 4.16 /MMBtu

TOTAL ENERGY

 -1,042 MMBtu $ 5,455 -
03 view
details		 SHIFT FROM DAYTIME TO NIGHTTIME OPERATION 2.3134 N $ 0 $ 2,831 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Demand Charge

 378 kW $ 7,556 $ 12.50 /kW

TOTAL ENERGY

 0 MMBtu $ 7,556 -

Personnel Changes

 - $ -4,725 -

TOTAL PRODUCTON

 - $ -4,725 -
04 view
details		 RECOVER HEAT FROM AIR COMPRESSOR 2.2434 N $ 1,000 $ 2,067 0.48
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 497 MMBtu $ 2,067 $ 4.16 /MMBtu

TOTAL ENERGY

 497 MMBtu $ 2,067 -
05 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 I $ 100 $ 1,815 0.06
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 26,964 kWh $ 1,224 $ 0.042 /kWh

- Demand Charge

 43 kW $ 591 $ 12.50 /kW

TOTAL ENERGY

 276 MMBtu $ 1,815 -
06 view
details		 INSTALL SPECTRAL REFLECTORS / DELAMP 2.7144 I $ 0 $ 1,781 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 28,429 kWh $ 1,289 $ 0.042 /kWh

- Demand Charge

 36 kW $ 492 $ 12.50 /kW

TOTAL ENERGY

 291 MMBtu $ 1,781 -
07 view
details		 PURCHASE GAS DIRECTLY FROM A CONTRACT GAS SUPPLIER 2.8113 N $ 500 $ 1,391 0.36
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 0 MMBtu $ 1,391 $ 4.16 /MMBtu

TOTAL ENERGY

 0 MMBtu $ 1,391 -
08 view
details		 CONVERT TO HIGH VOLUME LOW PRESSURE (HVLP) PAINT GUNS 3.2123 N $ 1,000 $ 872 1.15
Energy Sources Yearly Reduction Yearly Savings Unit Price

Ancillary Material Cost

 - $ 872 -

TOTAL PRODUCTON

 - $ 872 -
09 view
details		 REDUCE VENTILATION AIR 2.7314 I $ 500 $ 648 0.77
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 1,465 kWh $ 68 $ 0.042 /kWh

Natural Gas

 139 MMBtu $ 580 $ 4.16 /MMBtu

TOTAL ENERGY

 154 MMBtu $ 648 -
10 view
details		 UTILIZE ENERGY-EFFICIENT BELTS AND OTHER IMPROVED MECHANISMS 2.4111 I $ 0 $ 278 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 3,224 kWh $ 141 $ 0.042 /kWh

- Demand Charge

 10 kW $ 137 $ 12.50 /kW

TOTAL ENERGY

 33 MMBtu $ 278 -