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Industrial Assessment Centers

Assessment #LE0235


Assessment Date02/22/2006
SIC3341
SIC DescriptionSecondary Nonferrous Metals
NAICS331314
NAICS DecriptionSecondary Smelting and Alloying of Aluminum
Principal ProductAluminum log billet and extrusions
Sales$69,000,000
# of Employees200
Plant Area (Sq.Ft.)150,000
Annual Production115,000,000 Pounds
Production Hrs. Annual8,400
Location (StatePA
Fiscal Year (Budget Year)2006
Yearly Energy Cost$2,387,812

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 9,008,640 KWh $403,741 $0.045

- Demand Charge

 17,613KW-Month/Year $177,506 $10.08

- Electricity Fees

 - $0 -

Natural Gas

 214,152 MMBtu $1,806,565 $8.44

Recommended Reduction in Usage & Costs

Energy Sources Yearly Usage Yearly Cost % Saved Unit Price

Electricity

 1,291,237 KWh $58,106 14% $0.045

- Demand Charge

 3,363 KW-Month/Year $33,903 19% $0.045

Natural Gas

 47,810 MMBtu $403,516 22% $8.44

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
1 view
details		 CONSIDER USE / PURCHASE OF BULK MATERIALS WHERE POSSIBLE 4.2110 N $3,000,000 $1,380,000 2.2
Energy Type Usage Savings Cost Savings
Production Increases 20 $1,380,000
2 view
details		 PREHEAT COMBUSTION AIR WITH WASTE HEAT 2.2442 I $95,000 $202,503 0.5
Energy Type Usage Savings Cost Savings
Natural Gas 23,993 $202,503
3 view
details		 UPGRADE OBSOLETE EQUIPMENT 2.4321 I $250,000 $192,971 1.3
Energy Type Usage Savings Cost Savings
Production Increases 3 $172,500
Natural Gas 853 $7,202
4 view
details		 USE ADJUSTABLE FREQUENCY DRIVE TO REPLACE MOTOR-GENERATOR SET 2.4142 N $36,000 $73,559 0.5
Energy Type Usage Savings Cost Savings
Electrical Consumption 996,724 $44,853
Electrical Demand 2,848 $28,706
5 view
details		 ADJUST BURNERS FOR EFFICIENT OPERATION 2.1133 I $100 $66,844 0.0
Energy Type Usage Savings Cost Savings
Natural Gas 7,920 $66,844
6 view
details		 ADJUST BURNERS FOR EFFICIENT OPERATION 2.1133 I $20,000 $63,349 0.3
Energy Type Usage Savings Cost Savings
Natural Gas 7,506 $63,349
7 view
details		 REPAIR FAULTY INSULATION IN FURNACES, BOILERS, ETC 2.1131 I $30,000 $22,786 1.3
Energy Type Usage Savings Cost Savings
Natural Gas 2,700 $22,786
8 view
details		 REDESIGN PROCESS 2.5194 N $1,000 $19,713 0.1
Energy Type Usage Savings Cost Savings
Natural Gas 2,336 $19,713
9 view
details		 USE / PURCHASE OPTIMUM SIZED COMPRESSOR 2.4226 I $6,000 $12,444 0.5
Energy Type Usage Savings Cost Savings
Electrical Consumption 193,395 $8,703
Electrical Demand 371 $3,741
10 view
details		 PREHEAT COMBUSTION AIR WITH WASTE HEAT 2.2442 N $15,000 $11,211 1.3
Energy Type Usage Savings Cost Savings
Natural Gas 1,328 $11,211
11 view
details		 REPAIR FAULTY INSULATION IN FURNACES, BOILERS, ETC 2.1131 I $7,500 $9,908 0.8
Energy Type Usage Savings Cost Savings
Natural Gas 1,174 $9,908
12 view
details		 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES 2.4236 I $1,000 $6,006 0.2
Energy Type Usage Savings Cost Savings
Electrical Consumption 101,118 $4,550
Electrical Demand 144 $1,456




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Content Last Updated: 11/13/2007