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

Industrial Assessment Centers

Assessment #WV0320


Assessment Year 2005
SIC 3366
SIC Description Copper Foundries
NAICS 331525
NAICS Description Copper Foundries (except Die-Casting)
Principal Product Machine Tool Products
Sales $ 35,000,000
# of Employees 165
Plant Area (Sq.Ft.) 104,000
Annual Production 10,400,000 Pieces
Production Hrs. Annual 6,656
Location (State) OH
Yearly Energy Cost $ 196,950

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 1,807,200 kWh $ 144,112 $ 0.080 /kWh

- Demand Charge

 4,966 kW $ 33,233 $ 6.69 /kW

- Electricity Fees

 - $ 593 -

Natural Gas

 1,735 MMBtu $ 19,012 $ 10.96 /MMBtu

TOTAL ENERGY

 20,258 MMBtu $ 196,950 $ 9.72 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 433,960 kWh
361,695 kWh		 $ 34,590
$ 28,839		 24.00 %
20.01 %		 $ 0.080 /kWh

- Demand Charge

 861 kW
715 kW		 $ 5,758
$ 4,782		 17.33 %
14.39 %		 $ 6.69 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 580 MMBtu
158 MMBtu		 $ 6,357
$ 1,732		 33.44 %
9.11 %		 $ 10.96 /MMBtu

TOTAL ENERGY

 5,028 MMBtu
3,865 MMBtu		 $ 46,705
$ 35,353		 23.71 %
17.95 %		 $ 9.72 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 30,000 $ 15,626 1.92
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 170,287 kWh $ 13,572 $ 0.080 /kWh

- Demand Charge

 307 kW $ 2,054 $ 6.69 /kW

TOTAL ENERGY

 1,745 MMBtu $ 15,626 -
02 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 5,805 $ 4,978 1.17
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 54,151 kWh $ 4,322 $ 0.080 /kWh

- Demand Charge

 98 kW $ 656 $ 6.69 /kW

TOTAL ENERGY

 555 MMBtu $ 4,978 -
03 view
details		 BURN WASTE OIL FOR HEAT 3.6124 N $ 4,000 $ 4,770 0.84
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 333 MMBtu $ 3,650 $ 10.96 /MMBtu

TOTAL ENERGY

 333 MMBtu $ 3,650 -

Other Liquid (non-haz)

 2,000 Gal $ 1,120 $ 0 /Gal

TOTAL WASTE

 - $ 1,120 -
04 view
details		 INSTALL OCCUPANCY SENSORS 2.7135 I $ 4,750 $ 4,359 1.09
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 47,517 kWh $ 3,784 $ 0.080 /kWh

- Demand Charge

 86 kW $ 575 $ 6.69 /kW

TOTAL ENERGY

 487 MMBtu $ 4,359 -
05 view
details		 USE COOLING TOWER OR ECONOMIZER TO REPLACE CHILLER COOLING 2.2614 I $ 2,700 $ 4,094 0.66
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 39,848 kWh $ 3,177 $ 0.080 /kWh

- Demand Charge

 137 kW $ 917 $ 6.69 /kW

TOTAL ENERGY

 408 MMBtu $ 4,094 -
06 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 N $ 0 $ 3,232 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 35,144 kWh $ 2,804 $ 0.080 /kWh

- Demand Charge

 64 kW $ 428 $ 6.69 /kW

TOTAL ENERGY

 360 MMBtu $ 3,232 -
07 view
details		 USE COMPRESSOR AIR FILTERS 2.4227 N $ 800 $ 2,183 0.37
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 23,780 kWh $ 1,896 $ 0.080 /kWh

- Demand Charge

 43 kW $ 287 $ 6.69 /kW

TOTAL ENERGY

 244 MMBtu $ 2,183 -
08 view
details		 RECOVER HEAT FROM AIR COMPRESSOR 2.2434 I $ 1,645 $ 1,732 0.95
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 158 MMBtu $ 1,732 $ 10.96 /MMBtu

TOTAL ENERGY

 158 MMBtu $ 1,732 -
09 view
details		 DEVELOP A REPAIR/REPLACE POLICY 2.4151 I $ 213 $ 1,621 0.13
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 24,026 kWh $ 1,929 $ 0.080 /kWh

- Demand Charge

 44 kW $ 292 $ 6.69 /kW

TOTAL ENERGY

 246 MMBtu $ 2,221 -

Personnel Changes

 - $ -600 -

TOTAL PRODUCTON

 - $ -600 -
10 view
details		 PREHEAT COMBUSTION AIR WITH WASTE HEAT 2.2442 N $ 955 $ 975 0.98
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 89 MMBtu $ 975 $ 10.96 /MMBtu

TOTAL ENERGY

 89 MMBtu $ 975 -
11 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 I $ 667 $ 728 0.92
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 8,322 kWh $ 654 $ 0.080 /kWh

- Demand Charge

 11 kW $ 74 $ 6.69 /kW

TOTAL ENERGY

 85 MMBtu $ 728 -
12 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 N $ 400 $ 487 0.82
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 5,290 kWh $ 420 $ 0.080 /kWh

- Demand Charge

 10 kW $ 67 $ 6.69 /kW

TOTAL ENERGY

 54 MMBtu $ 487 -
13 view
details		 UTILIZE A LESS EXPENSIVE COOLING METHOD 2.2628 N $ 488 $ 474 1.03
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 4,242 kWh $ 327 $ 0.080 /kWh

- Demand Charge

 22 kW $ 147 $ 6.69 /kW

TOTAL ENERGY

 43 MMBtu $ 474 -
14 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 I $ 430 $ 457 0.94
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 4,982 kWh $ 397 $ 0.080 /kWh

- Demand Charge

 9 kW $ 60 $ 6.69 /kW

TOTAL ENERGY

 51 MMBtu $ 457 -
15 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 80 $ 438 0.18
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 12,562 kWh $ 1,004 $ 0.080 /kWh

- Demand Charge

 23 kW $ 154 $ 6.69 /kW

TOTAL ENERGY

 129 MMBtu $ 1,158 -

Personnel Changes

 - $ -600 -

Primary Raw Material

 - $ -120 -

TOTAL PRODUCTON

 - $ -720 -
16 view
details		 REPAIR FURNACES AND OVEN DOORS SO THAT THEY SEAL EFFICIENTLY 2.1135 N $ 26 $ 351 0.07
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 3,809 kWh $ 304 $ 0.080 /kWh

- Demand Charge

 7 kW $ 47 $ 6.69 /kW

TOTAL ENERGY

 39 MMBtu $ 351 -