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

Industrial Assessment Centers

Assessment #WV0407


Assessment Year 2010
SIC 2869
SIC Description Industrial Organic Chemicals, Nec
NAICS 325199
NAICS Description All Other Basic Organic Chemical Manufacturing
Principal Product organo functional silanes
Sales $ 10,000,000
# of Employees 210
Plant Area (Sq.Ft.) 457,000
Annual Production 38,000,000 Pounds
Production Hrs. Annual 8,760
Location (State) WV
Yearly Energy Cost $ 6,710,622

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 55,103,450 kWh $ 1,655,601 $ 0.030 /kWh

- Demand Charge

 88,405 kW $ 877,398 $ 9.92 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 560,430 MMBtu $ 4,177,623 $ 7.45 /MMBtu

TOTAL ENERGY

 1,125,240 MMBtu $ 6,710,622 $ 5.96 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 42,823,956 kWh
647,994 kWh		 $ 1,285,678
$ 19,473		 77.66 %
1.18 %		 $ 0.030 /kWh

- Demand Charge

 58,788 kW
912 kW		 $ 583,184
$ 9,054		 66.47 %
1.03 %		 $ 9.92 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 -42,113 MMBtu
34,721 MMBtu		 $ -313,743
$ 258,671		 -7.51 %
6.19 %		 $ 7.45 /MMBtu

TOTAL ENERGY

 396,832 MMBtu
41,363 MMBtu		 $ 1,555,119
$ 287,198		 23.17 %
4.28 %		 $ 5.96 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 INSTALL WASTE HEAT BOILER TO PRODUCE STEAM 2.2423 N $ 798,300 $ 622,016 1.28
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 -73,518 kWh $ -3,392 $ 0.030 /kWh

Natural Gas

 86,632 MMBtu $ 645,408 $ 7.45 /MMBtu

TOTAL ENERGY

 85,878 MMBtu $ 642,016 -

Personnel Changes

 - $ -20,000 -

TOTAL PRODUCTON

 - $ -20,000 -
02 view
details		 USE STEAM PRESSURE REDUCTION TO GENERATE POWER 2.3321 N $ 1,200,000 $ 542,540 2.21
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 42,249,480 kWh $ 1,269,597 $ 0.030 /kWh

- Demand Charge

 57,876 kW $ 574,130 $ 9.92 /kW

Natural Gas

 -174,656 MMBtu $ -1,301,187 $ 7.45 /MMBtu

TOTAL ENERGY

 258,401 MMBtu $ 542,540 -
03 view
details		 REPAIR OR REPLACE STEAM TRAPS 2.2113 I $ 5,500 $ 235,631 0.02
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 34,721 MMBtu $ 258,671 $ 7.45 /MMBtu

TOTAL ENERGY

 34,721 MMBtu $ 258,671 -

Personnel Changes

 - $ -23,040 -

TOTAL PRODUCTON

 - $ -23,040 -
04 view
details		 USE RADIANT HEATER FOR SPOT HEATING 2.7231 N $ 96,200 $ 43,962 2.19
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 5,901 MMBtu $ 43,962 $ 7.45 /MMBtu

TOTAL ENERGY

 5,901 MMBtu $ 43,962 -
05 view
details		 DIRECT WARMEST AIR TO COMBUSTION INTAKE 2.1213 N $ 7,920 $ 20,301 0.39
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 2,725 MMBtu $ 20,301 $ 7.45 /MMBtu

TOTAL ENERGY

 2,725 MMBtu $ 20,301 -
06 view
details		 RECOVER WASTE HEAT FROM EQUIPMENT 2.2437 N $ 43,400 $ 19,102 2.27
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 2,564 MMBtu $ 19,102 $ 7.45 /MMBtu

TOTAL ENERGY

 2,564 MMBtu $ 19,102 -
07 view
details		 DEVELOP A REPAIR/REPLACE POLICY 2.4151 I $ 772 $ 10,842 0.07
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 266,069 kWh $ 7,995 $ 0.030 /kWh

- Demand Charge

 364 kW $ 3,615 $ 9.92 /kW

TOTAL ENERGY

 2,727 MMBtu $ 11,610 -

Personnel Changes

 - $ -768 -

TOTAL PRODUCTON

 - $ -768 -
08 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 I $ 17,348 $ 5,003 3.47
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 108,939 kWh $ 3,274 $ 0.030 /kWh

- Demand Charge

 174 kW $ 1,729 $ 9.92 /kW

TOTAL ENERGY

 1,117 MMBtu $ 5,003 -
09 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 7,158 $ 3,209 2.23
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 73,435 kWh $ 2,207 $ 0.030 /kWh

- Demand Charge

 101 kW $ 1,002 $ 9.92 /kW

TOTAL ENERGY

 753 MMBtu $ 3,209 -
10 view
details		 ESTABLISH A PREDICTIVE MAINTENANCE PROGRAM 2.4157 I $ 1,000 $ 4,353 0.23
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 199,551 kWh $ 5,997 $ 0.030 /kWh

- Demand Charge

 273 kW $ 2,708 $ 9.92 /kW

TOTAL ENERGY

 2,045 MMBtu $ 8,705 -

Personnel Changes

 - $ -4,352 -

TOTAL PRODUCTON

 - $ -4,352 -