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

Industrial Assessment Centers

Assessment #WV0414


Assessment Year 2010
SIC 3559
SIC Description Special Industry Machinery, Nec
NAICS 333999
NAICS Description All Other Miscellaneous General Purpose Machinery Manufacturing
Principal Product PVC fill media for cooling tower and waste water treatment
Sales $ 25,000,000
# of Employees 92
Plant Area (Sq.Ft.) 120,000
Annual Production 22,000,000 Pounds
Production Hrs. Annual 4,160
Location (State) WV
Yearly Energy Cost $ 394,637

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 4,570,983 kWh $ 180,561 $ 0.040 /kWh

- Demand Charge

 15,498 kW $ 165,446 $ 10.68 /kW

- Electricity Fees

 - $ 0 -

Natural Gas

 4,461 MMBtu $ 48,630 $ 10.90 /MMBtu

TOTAL ENERGY

 51,314 MMBtu $ 394,637 $ 7.69 /MMBtu

Recommended Reduction in Usage & Costs

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

Electricity

 480,245 kWh
343,293 kWh		 $ 18,970
$ 13,561		 10.51 %
7.51 %		 $ 0.040 /kWh

- Demand Charge

 1,440 kW
1,007 kW		 $ 15,379
$ 10,755		 9.30 %
6.50 %		 $ 10.68 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 2,984 MMBtu
160 MMBtu		 $ 32,137
$ 1,723		 66.08 %
3.54 %		 $ 10.90 /MMBtu

TOTAL ENERGY

 7,905 MMBtu
3,678 MMBtu		 $ 66,486
$ 26,039		 16.85 %
6.60 %		 $ 7.69 /MMBtu

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 RECOVER HEAT FROM OVEN EXHAUST / KILNS 2.2432 N $ 18,300 $ 22,889 0.80
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 -9,053 kWh $ -358 $ 0.040 /kWh

Natural Gas

 2,191 MMBtu $ 23,597 $ 10.90 /MMBtu

TOTAL ENERGY

 2,098 MMBtu $ 23,239 -

Personnel Changes

 - $ -350 -

TOTAL PRODUCTON

 - $ -350 -
02 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 42,420 $ 12,304 3.45
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 174,953 kWh $ 6,911 $ 0.040 /kWh

- Demand Charge

 505 kW $ 5,393 $ 10.68 /kW

TOTAL ENERGY

 1,793 MMBtu $ 12,304 -
03 view
details		 REDUCE FLUID FLOW RATES 2.5123 I $ 280 $ 7,185 0.04
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 102,114 kWh $ 4,034 $ 0.040 /kWh

- Demand Charge

 295 kW $ 3,151 $ 10.68 /kW

TOTAL ENERGY

 1,047 MMBtu $ 7,185 -
04 view
details		 USE MULTIPLE SPEED MOTORS OR AFD FOR VARIABLE PUMP, BLOWER AND COMPRESSOR LOADS 2.4141 N $ 15,400 $ 6,064 2.54
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 86,191 kWh $ 3,405 $ 0.040 /kWh

- Demand Charge

 249 kW $ 2,659 $ 10.68 /kW

TOTAL ENERGY

 883 MMBtu $ 6,064 -
05 view
details		 RECOVER HEAT FROM COMPRESSED AIR DRYERS 2.2435 N $ 400 $ 3,414 0.12
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 317 MMBtu $ 3,414 $ 10.90 /MMBtu

TOTAL ENERGY

 317 MMBtu $ 3,414 -
06 view
details		 USE RADIANT HEATER FOR SPOT HEATING 2.7231 N $ 5,310 $ 3,403 1.56
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 316 MMBtu $ 3,403 $ 10.90 /MMBtu

TOTAL ENERGY

 316 MMBtu $ 3,403 -
07 view
details		 UTILIZE A LESS EXPENSIVE COOLING METHOD 2.2628 N $ 14,000 $ 2,505 5.59
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 33,953 kWh $ 1,341 $ 0.040 /kWh

- Demand Charge

 109 kW $ 1,164 $ 10.68 /kW

TOTAL ENERGY

 348 MMBtu $ 2,505 -
08 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 I $ 3,614 $ 1,467 2.46
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 18,475 kWh $ 730 $ 0.040 /kWh

- Demand Charge

 69 kW $ 737 $ 10.68 /kW

TOTAL ENERGY

 189 MMBtu $ 1,467 -
09 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 N $ 835 $ 1,409 0.59
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 20,001 kWh $ 790 $ 0.040 /kWh

- Demand Charge

 58 kW $ 619 $ 10.68 /kW

TOTAL ENERGY

 205 MMBtu $ 1,409 -
10 view
details		 RECOVER MECHANICAL ENERGY 2.4311 I $ 1,000 $ 1,362 0.73
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 23,935 kWh $ 945 $ 0.040 /kWh

- Demand Charge

 69 kW $ 737 $ 10.68 /kW

TOTAL ENERGY

 245 MMBtu $ 1,682 -

Personnel Changes

 - $ -320 -

TOTAL PRODUCTON

 - $ -320 -
11 view
details		 REDUCE SPACE CONDITIONING DURING NON-WORKING HOURS 2.7224 I $ 1,070 $ 1,335 0.80
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 124 MMBtu $ 1,335 $ 10.90 /MMBtu

TOTAL ENERGY

 124 MMBtu $ 1,335 -
12 view
details		 DEVELOP A REPAIR/REPLACE POLICY 2.4151 I $ 740 $ 1,318 0.56
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 23,816 kWh $ 941 $ 0.040 /kWh

- Demand Charge

 69 kW $ 737 $ 10.68 /kW

TOTAL ENERGY

 244 MMBtu $ 1,678 -

Personnel Changes

 - $ -360 -

TOTAL PRODUCTON

 - $ -360 -
13 view
details		 IMPROVE LUBRICATION PRACTICES 2.4312 N $ 465 $ 413 1.13
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 5,860 kWh $ 231 $ 0.040 /kWh

- Demand Charge

 17 kW $ 182 $ 10.68 /kW

TOTAL ENERGY

 60 MMBtu $ 413 -
14 view
details		 USE PROPER THICKNESS OF INSULATION ON BUILDING ENVELOPE 2.7492 I $ 1,735 $ 388 4.47
Energy Sources Yearly Reduction Yearly Savings Unit Price

Natural Gas

 36 MMBtu $ 388 $ 10.90 /MMBtu

TOTAL ENERGY

 36 MMBtu $ 388 -