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

Industrial Assessment Centers

Assessment #WV0403


Assessment Year 2010
SIC 2899
SIC Description Chemical Preparations, Nec
NAICS 325188
NAICS Description All Other Basic Inorganic Chemical Manufacturing
Principal Product Chemical Polymers and Blends
Sales $ 260,000,000
# of Employees 176
Plant Area (Sq.Ft.) 368,650
Annual Production 20,000,000 Pounds
Production Hrs. Annual 6,240
Location (State) PA
Yearly Energy Cost $ 693,245

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 6,833,122 kWh $ 543,841 $ 0.080 /kWh

- Demand Charge

 17,388 kW $ 29,690 $ 1.71 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 32,113 MMBtu $ 119,714 $ 3.73 /MMBtu

TOTAL ENERGY

 102,153 MMBtu $ 693,245 $ 6.79 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 1,213,390 kWh
1,055,378 kWh		 $ 96,574
$ 83,998		 17.76 %
15.45 %		 $ 0.080 /kWh

- Demand Charge

 2,444 kW
2,140 kW		 $ 4,180
$ 3,660		 14.08 %
12.33 %		 $ 1.71 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 2,880 MMBtu
0 MMBtu		 $ 10,742
$ 0		 8.97 %
0.00 %		 $ 3.73 /MMBtu

TOTAL ENERGY

 15,317 MMBtu
10,818 MMBtu		 $ 111,496
$ 87,658		 16.08 %
12.64 %		 $ 6.79 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 UTILIZE A LESS EXPENSIVE COOLING METHOD 2.2628 I $ 55,000 $ 45,685 1.20
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 549,827 kWh $ 43,761 $ 0.080 /kWh

- Demand Charge

 1,125 kW $ 1,924 $ 1.71 /kW

TOTAL ENERGY

 5,636 MMBtu $ 45,685 -
02 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 I $ 52,453 $ 18,050 2.91
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 216,904 kWh $ 17,263 $ 0.080 /kWh

- Demand Charge

 460 kW $ 787 $ 1.71 /kW

TOTAL ENERGY

 2,223 MMBtu $ 18,050 -
03 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 70,410 $ 18,231 3.86
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 219,976 kWh $ 17,508 $ 0.080 /kWh

- Demand Charge

 423 kW $ 723 $ 1.71 /kW

TOTAL ENERGY

 2,255 MMBtu $ 18,231 -
04 view
details		 IMPROVE LUBRICATION PRACTICES 2.4312 N $ 5,823 $ 9,486 0.61
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 114,465 kWh $ 9,110 $ 0.080 /kWh

- Demand Charge

 220 kW $ 376 $ 1.71 /kW

TOTAL ENERGY

 1,173 MMBtu $ 9,486 -
05 view
details		 USE RADIANT HEATER FOR SPOT HEATING 2.7231 N $ 20,500 $ 4,543 4.51
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,218 MMBtu $ 4,543 $ 3.73 /MMBtu

TOTAL ENERGY

 1,218 MMBtu $ 4,543 -
06 view
details		 ELIMINATE OR REDUCE COMPRESSED AIR USED FOR COOLING, AGITATING LIQUIDS, MOVING PRODUCT, OR DRYING 2.4232 N $ 8,756 $ 3,610 2.43
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 43,547 kWh $ 3,466 $ 0.080 /kWh

- Demand Charge

 84 kW $ 144 $ 1.71 /kW

TOTAL ENERGY

 446 MMBtu $ 3,610 -
07 view
details		 RECYCLE AIR FOR HEATING, VENTILATION AND AIR CONDITIONING 2.7313 N $ 8,600 $ 2,357 3.65
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 1,034 MMBtu $ 3,857 $ 3.73 /MMBtu

TOTAL ENERGY

 1,034 MMBtu $ 3,857 -

Administrative Changes

 - $ -1,500 -

TOTAL PRODUCTON

 - $ -1,500 -
08 view
details		 USE WASTE HEAT FROM HOT FLUE GASES TO PREHEAT COMBUSTION AIR 2.2411 N $ 10,700 $ 2,342 4.57
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 628 MMBtu $ 2,342 $ 3.73 /MMBtu

TOTAL ENERGY

 628 MMBtu $ 2,342 -
09 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 I $ 1,620 $ 2,274 0.71
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 27,428 kWh $ 2,183 $ 0.080 /kWh

- Demand Charge

 53 kW $ 91 $ 1.71 /kW

TOTAL ENERGY

 281 MMBtu $ 2,274 -
10 view
details		 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED 2.4231 I $ 110 $ 2,238 0.05
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 26,999 kWh $ 2,149 $ 0.080 /kWh

- Demand Charge

 52 kW $ 89 $ 1.71 /kW

TOTAL ENERGY

 277 MMBtu $ 2,238 -
11 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $ 748 $ 1,180 0.63
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 14,244 kWh $ 1,134 $ 0.080 /kWh

- Demand Charge

 27 kW $ 46 $ 1.71 /kW

TOTAL ENERGY

 146 MMBtu $ 1,180 -