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

Industrial Assessment Centers

Assessment #WV0344


Assessment Year 2006
SIC 3674
SIC Description Semiconductors And Related Devices
NAICS 334413
NAICS Description Semiconductor and Related Device Manufacturing
Principal Product photovoltaic cells and wafers
Sales $ 75,000,000
# of Employees 480
Plant Area (Sq.Ft.) 180,000
Annual Production 65 Not Available
Production Hrs. Annual 8,400
Location (State) MD
Yearly Energy Cost $ 3,258,791

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 47,183,065 kWh $ 2,900,815 $ 0.061 /kWh

- Demand Charge

 76,210 kW $ 192,283 $ 2.52 /kW

- Electricity Fees

 - $ 87,833 -

Natural Gas

 6,106 MMBtu $ 77,860 $ 12.75 /MMBtu

TOTAL ENERGY

 489,732 MMBtu $ 3,258,791 $ 6.65 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 2,888,612 kWh
2,275,111 kWh		 $ 182,974
$ 144,109		 6.31 %
4.97 %		 $ 0.061 /kWh

- Demand Charge

 3,895 kW
3,017 kW		 $ 9,817
$ 7,604		 5.11 %
3.95 %		 $ 2.52 /kW

- Electricity Fees

 - $ 18,000
$ 18,000		 20.49 %
20.49 %		 -

Natural Gas

 406 MMBtu
406 MMBtu		 $ 5,177
$ 5,177		 6.65 %
6.65 %		 $ 12.75 /MMBtu

TOTAL ENERGY

 30,015 MMBtu
23,727 MMBtu		 $ 215,968
$ 174,890		 6.63 %
5.37 %		 $ 6.65 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 DEVELOP A REPAIR/REPLACE POLICY 2.4151 I $ 1,472 $ 50,956 0.03
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 802,820 kWh $ 50,850 $ 0.061 /kWh

- Demand Charge

 1,147 kW $ 2,890 $ 2.52 /kW

TOTAL ENERGY

 8,229 MMBtu $ 53,740 -

Personnel Changes

 - $ -2,784 -

TOTAL PRODUCTON

 - $ -2,784 -
02 view
details		 ESTABLISH A PREDICTIVE MAINTENANCE PROGRAM 2.4157 I $ 1,000 $ 41,030 0.02
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 642,256 kWh $ 40,680 $ 0.061 /kWh

- Demand Charge

 917 kW $ 2,312 $ 2.52 /kW

TOTAL ENERGY

 6,583 MMBtu $ 42,992 -

Personnel Changes

 - $ -1,962 -

TOTAL PRODUCTON

 - $ -1,962 -
03 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 N $ 15 $ 30,895 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 461,568 kWh $ 29,232 $ 0.061 /kWh

- Demand Charge

 660 kW $ 1,663 $ 2.52 /kW

TOTAL ENERGY

 4,731 MMBtu $ 30,895 -
04 view
details		 UTILIZE A LESS EXPENSIVE COOLING METHOD 2.2628 I $ 27,387 $ 22,182 1.23
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 325,523 kWh $ 20,620 $ 0.061 /kWh

- Demand Charge

 620 kW $ 1,562 $ 2.52 /kW

TOTAL ENERGY

 3,337 MMBtu $ 22,182 -
05 view
details		 USE POWER FACTOR CONTROLLERS 2.3211 I $ 32,500 $ 18,000 1.81
Energy Sources Yearly Reduction Yearly Savings Unit Price

- Electricity Fees

 - $ 18,000 -

TOTAL ENERGY

 0 MMBtu $ 18,000 -
06 view
details		 USE COOLING TOWER OR ECONOMIZER TO REPLACE CHILLER COOLING 2.2614 I $ 26,662 $ 16,147 1.65
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 254,910 kWh $ 16,147 $ 0.061 /kWh

TOTAL ENERGY

 2,613 MMBtu $ 16,147 -
07 view
details		 CHILL WATER TO THE HIGHEST TEMPERATURE POSSIBLE 2.2625 N $ 44 $ 8,710 0.01
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 130,181 kWh $ 8,241 $ 0.061 /kWh

- Demand Charge

 186 kW $ 469 $ 2.52 /kW

TOTAL ENERGY

 1,334 MMBtu $ 8,710 -
08 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 12,137 $ 6,355 1.91
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 94,917 kWh $ 6,012 $ 0.061 /kWh

- Demand Charge

 136 kW $ 343 $ 2.52 /kW

TOTAL ENERGY

 973 MMBtu $ 6,355 -
09 view
details		 UTILIZE ENERGY-EFFICIENT BELTS AND OTHER IMPROVED MECHANISMS 2.4111 I $ 0 $ 5,629 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 84,091 kWh $ 5,326 $ 0.061 /kWh

- Demand Charge

 120 kW $ 303 $ 2.52 /kW

TOTAL ENERGY

 862 MMBtu $ 5,629 -
10 view
details		 RECOVER HEAT FROM AIR COMPRESSOR 2.2434 I $ 1,896 $ 5,177 0.37
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 406 MMBtu $ 5,177 $ 12.75 /MMBtu

TOTAL ENERGY

 406 MMBtu $ 5,177 -
11 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 I $ 436 $ 3,355 0.13
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 50,103 kWh $ 3,174 $ 0.061 /kWh

- Demand Charge

 72 kW $ 181 $ 2.52 /kW

TOTAL ENERGY

 514 MMBtu $ 3,355 -
12 view
details		 ISOLATE HOT OR COLD EQUIPMENT 2.2522 N $ 1,500 $ 1,256 1.19
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 18,752 kWh $ 1,188 $ 0.061 /kWh

- Demand Charge

 27 kW $ 68 $ 2.52 /kW

TOTAL ENERGY

 192 MMBtu $ 1,256 -
13 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 1,811 $ 1,197 1.51
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 20,491 kWh $ 1,300 $ 0.061 /kWh

- Demand Charge

 5 kW $ 13 $ 2.52 /kW

TOTAL ENERGY

 210 MMBtu $ 1,313 -

Personnel Changes

 - $ -116 -

TOTAL PRODUCTON

 - $ -116 -
14 view
details		 ELIMINATE OR REDUCE COMPRESSED AIR USED FOR COOLING, AGITATING LIQUIDS, MOVING PRODUCT, OR DRYING 2.4232 N $ 100 $ 217 0.46
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 3,000 kWh $ 204 $ 0.061 /kWh

- Demand Charge

 5 kW $ 13 $ 2.52 /kW

TOTAL ENERGY

 31 MMBtu $ 217 -