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

Industrial Technologies Program

Industrial Assessment Centers

Assessment #WV0124


Assessment Year 1997
SIC 3823
SIC Description Process Control Instruments
NAICS
NAICS Description
Principal Product Burners
Sales $ 16,400,000
# of Employees 135
Plant Area (Sq.Ft.) 118,773
Annual Production 2,000 Pieces
Production Hrs. Annual 4,704
Location (State) PA
Yearly Energy Cost $ 317,545

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 2,403,576 kWh $ 92,922 $ 0.039 /kWh

- Demand Charge

 7,302 kW $ 118,911 $ 16.28 /kW

- Electricity Fees

 - $ -7,046 -

Natural Gas

 19,444 MMBtu $ 112,758 $ 5.80 /MMBtu

TOTAL ENERGY

 44,081 MMBtu $ 317,545 $ 7.20 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 70,340 kWh
150,645 kWh		 $ 2,525
$ 5,386		 2.72 %
5.80 %		 $ 0.039 /kWh

- Demand Charge

 153 kW
153 kW		 $ 2,847
$ 2,847		 2.39 %
2.39 %		 $ 16.28 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 3,831 MMBtu
1,348 MMBtu		 $ 22,220
$ 7,818		 19.71 %
6.93 %		 $ 5.80 /MMBtu

TOTAL ENERGY

 4,552 MMBtu
2,892 MMBtu		 $ 27,592
$ 16,051		 8.69 %
5.05 %		 $ 7.20 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 361 $ 1,851 0.20
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 17,292 kWh $ 618 $ 0.039 /kWh

- Demand Charge

 66 kW $ 1,233 $ 16.28 /kW

TOTAL ENERGY

 177 MMBtu $ 1,851 -
02 view
details		 USE MOST EFFICIENT TYPE OF ELECTRIC MOTORS 2.4133 I $ 1,740 $ 1,835 0.95
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 6,155 kWh $ 221 $ 0.039 /kWh

- Demand Charge

 87 kW $ 1,614 $ 16.28 /kW

TOTAL ENERGY

 63 MMBtu $ 1,835 -
03 view
details		 UTILIZE ENERGY-EFFICIENT BELTS AND OTHER IMPROVED MECHANISMS 2.4111 I $ 1,080 $ 391 2.76
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 10,844 kWh $ 391 $ 0.039 /kWh

TOTAL ENERGY

 111 MMBtu $ 391 -
04 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 N $ 290 $ 150 1.93
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 4,103 kWh $ 150 $ 0.039 /kWh

TOTAL ENERGY

 42 MMBtu $ 150 -
05 view
details		 REDUCE HOT WATER TEMPERATURE TO THE MINIMUM REQUIRED 2.6121 I $ 0 $ 5,413 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 151,524 kWh $ 5,413 $ 0.039 /kWh

TOTAL ENERGY

 1,553 MMBtu $ 5,413 -
06 view
details		 REDUCE BUILDING VENTILATION AIR TO MINIMUM SAFE LEVELS 2.7315 I $ 6,200 $ 7,818 0.79
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,348 MMBtu $ 7,818 $ 5.80 /MMBtu

TOTAL ENERGY

 1,348 MMBtu $ 7,818 -
07 view
details		 INSULATE GLAZING, WALLS, CEILINGS, AND ROOFS 2.7491 N $ 3,268 $ 1,549 2.11
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 267 MMBtu $ 1,549 $ 5.80 /MMBtu

TOTAL ENERGY

 267 MMBtu $ 1,549 -
08 view
details		 TURN OFF EQUIPMENT DURING BREAKS, REDUCE OPERATING TIME 2.6212 N $ 0 $ 11,865 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 7,913 kWh $ 288 $ 0.039 /kWh

Natural Gas

 1,996 MMBtu $ 11,577 $ 5.80 /MMBtu

TOTAL ENERGY

 2,077 MMBtu $ 11,865 -
09 view
details		 RECOVER HEAT FROM AIR COMPRESSOR 2.2434 N $ 800 $ 1,276 0.63
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 220 MMBtu $ 1,276 $ 5.80 /MMBtu

TOTAL ENERGY

 220 MMBtu $ 1,276 -
10 view
details		 INSTALL EQUIPMENT (eg COMPACTOR) TO REDUCE DISPOSAL COSTS 3.6193 N $ 11,000 $ 3,097 3.55
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 -293 kWh $ -13 $ 0.039 /kWh

TOTAL ENERGY

 -3 MMBtu $ -13 -

Personnel Changes

 - $ -490 -

Administrative Changes

 - $ 3,600 -

TOTAL PRODUCTON

 - $ 3,110 -
11 view
details		 LEASE / PURCHASE BALER; SELL CARDBOARD TO RECYCLER 3.5315 N $ 10,000 $ 3,924 2.55
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 -586 kWh $ -20 $ 0.039 /kWh

TOTAL ENERGY

 -6 MMBtu $ -20 -

Personnel Changes

 - $ -980 -

Administrative Changes

 - $ 3,429 -

Ancillary Material Cost

 - $ 1,495 -

TOTAL PRODUCTON

 - $ 3,944 -
12 view
details		 USE CLOSED CYCLE PROCESS TO MINIMIZE WASTE WATER PRODUCTION 3.4111 I $ 1,570 $ 7,143 0.22
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 -35,170 kWh $ -1,257 $ 0.039 /kWh

TOTAL ENERGY

 -360 MMBtu $ -1,257 -

Administrative Changes

 - $ 8,400 -

TOTAL PRODUCTON

 - $ 8,400 -
13 view
details		 CHANGE OPERATING CONDITIONS 4.6320 N $ 5,000 $ 20,734 0.24
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 -91,442 kWh $ -3,266 $ 0.039 /kWh

TOTAL ENERGY

 -937 MMBtu $ -3,266 -

Personnel Changes

 - $ -48,000 -

Ancillary Material Cost

 - $ -48,000 -

Primary Product

 - $ 120,000 -

TOTAL PRODUCTON

 - $ 24,000 -