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IAC Assessment: AM0368
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IAC Assessment: AM0368
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IAC Center Texas A&M, College Station
Assessment Year 2000
Principal Product Fiberglass Strands for reinforcement
NAICS n/a
SIC 3229 - Pressed And Blown Glass, Nec
Sales $100,000,000-$500,000,000
# of Employees 765
Plant Area (Sq.Ft.) 500,000
Annual Production 275,000,000 Pounds
Production Hrs. Annual 8,760
Location (State) TX
Source Yearly Cost Usage Unit Unit Cost
Electricity Usage $3,858,395 188,208,092 kWh $0.02
Electricity Demand $1,626,729 271,300 kW-months/year $6.00
Natural Gas $2,752,413 1,308,600 MMBtu $2.10
TOTAL ENERGY COSTS $8,308,784
RECOMMENDED SAVINGS* $2,713,841 *Non-energy impacts
included in savings.
See recommendations below
IMPLEMENTED SAVINGS* $167,001
#|Description Savings
Cost
Status Electricity Usage Electricity Demand Natural Gas Fuel Oil #2 Water Disposal Solid Waste (non-haz) Personnel Changes Administrative Changes Primary Raw Material Ancillary Material Cost Water Consumption Primary Product By-product Production Electricity Usage Electricity Demand Natural Gas Fuel Oil #2 Water Disposal Solid Waste (non-haz) Personnel Changes Administrative Changes Primary Raw Material Ancillary Material Cost Water Consumption Primary Product By-product Production
$ kWh $ kW-months/year $ MMBtu $ MMBtu $ Tgal $ lb $ $ $ $ $ $ $ $ $ Tgal $ $ $ $
01: 3.5313 INCREASE AMOUNT OF WASTE RECOVERED FOR RESALE Savings:
$1,224,000
Cost:
$234,000
- - - - - - $(-32,000) (-24,960) - - $116,000 11,100,000 $(-77,000) - - - - - - - - - $1,217,000 - - - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
$(-32,000)
(-24,960)
MMBtu
-
-
Tgal
$116,000
11,100,000
lb
$(-77,000)
-
$
-
-
$
-
-
$
-
-
$
-
-
Tgal
$1,217,000
-
$
-
-
$
02: 3.5313 INCREASE AMOUNT OF WASTE RECOVERED FOR RESALE Savings:
$339,020
Cost:
$481,000
- - - - - - - - - - $180,020 26,500,000 - - - - - - - - - - - - $159,000 - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
MMBtu
-
-
Tgal
$180,020
26,500,000
lb
-
-
$
-
-
$
-
-
$
-
-
$
-
-
Tgal
-
-
$
$159,000
-
$
03: 3.1192 REDUCE SCRAP PRODUCTION Savings:
$327,000
Cost:
$45,000
$25,000 1,219,226 - - - - - - - - - - $73,000 - - - $126,000 - - - - - $103,000 - - - $25,000
1,219,226
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
MMBtu
-
-
Tgal
-
-
lb
$73,000
-
$
-
-
$
$126,000
-
$
-
-
$
-
-
Tgal
$103,000
-
$
-
-
$
04: 3.7211 MODIFY MATERIAL APPLICATION METHODS Savings:
$207,000
Cost:
-
- - - - - - - - - - - - - - - - - - $207,000 - - - - - - - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
MMBtu
-
-
Tgal
-
-
lb
-
-
$
-
-
$
-
-
$
$207,000
-
$
-
-
Tgal
-
-
$
-
-
$
05: 4.231 PURCHASE EQUIPMENT INSTEAD OF LEASING Savings:
$131,000
Cost:
$317,000
- - - - - - - - - - - - - - $131,000 - - - - - - - - - - - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
MMBtu
-
-
Tgal
-
-
lb
-
-
$
$131,000
-
$
-
-
$
-
-
$
-
-
Tgal
-
-
$
-
-
$
06: 3.1192 REDUCE SCRAP PRODUCTION Savings:
$54,000
Cost:
$120,000
- - - - - - - - - - - - $(-182,000) - - - $98,000 - - - - - $138,000 - - - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
MMBtu
-
-
Tgal
-
-
lb
$(-182,000)
-
$
-
-
$
$98,000
-
$
-
-
$
-
-
Tgal
$138,000
-
$
-
-
$
07: 3.1191 CHANGE PROCEDURES / EQUIPMENT / OPERATING CONDITIONS Savings:
$85,560
Cost:
$3,500
- - - - - - - - $3,120 2,365,200 - - $(-940) - $80,000 - - - - - $3,380 - - - - - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
MMBtu
$3,120
2,365,200
Tgal
-
-
lb
$(-940)
-
$
$80,000
-
$
-
-
$
-
-
$
$3,380
-
Tgal
-
-
$
-
-
$
08: 2.2414 USE WASTE HEAT FROM HOT FLUE GASES TO PREHEAT Savings:
$85,000
Cost:
$100,000
- - - - $85,000 40,200 - - - - - - - - - - - - - - - - - - - - -
-
kWh
-
-
kW-months/year
$85,000
40,200
MMBtu
-
-
MMBtu
-
-
Tgal
-
-
lb
-
-
$
-
-
$
-
-
$
-
-
$
-
-
Tgal
-
-
$
-
-
$
09: 3.4113 TREAT AND REUSE RINSE WATERS Savings:
$80,300
Cost:
$242,500
- - - - - - - - $38,500 29,200,000 - - - - - - - - - - $41,800 - - - - - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
MMBtu
$38,500
29,200,000
Tgal
-
-
lb
-
-
$
-
-
$
-
-
$
-
-
$
$41,800
-
Tgal
-
-
$
-
-
$
10: 3.6192 USE A LESS EXPENSIVE METHOD OF WASTE REMOVAL Savings:
$72,000
Cost:
$68,000
- - - - - - - - - - - - $72,000 - - - - - - - - - - - - - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
MMBtu
-
-
Tgal
-
-
lb
$72,000
-
$
-
-
$
-
-
$
-
-
$
-
-
Tgal
-
-
$
-
-
$
11: 2.7231 USE RADIANT HEATER FOR SPOT HEATING Savings:
$72,000
Cost:
$26,400
- - - - $72,000 33,994 - - - - - - - - - - - - - - - - - - - - -
-
kWh
-
-
kW-months/year
$72,000
33,994
MMBtu
-
-
MMBtu
-
-
Tgal
-
-
lb
-
-
$
-
-
$
-
-
$
-
-
$
-
-
Tgal
-
-
$
-
-
$
12: 2.7124 MAKE A PRACTICE OF TURNING OFF LIGHTS WHEN NOT NEEDED Savings:
$10,591
Cost:
-
$6,048 302,462 $4,543 761 - - - - - - - - - - - - - - - - - - - - - - $6,048
302,462
kWh
$4,543
761
kW-months/year
-
-
MMBtu
-
-
MMBtu
-
-
Tgal
-
-
lb
-
-
$
-
-
$
-
-
$
-
-
$
-
-
Tgal
-
-
$
-
-
$
13: 2.4314 USE SYNTHETIC LUBRICANT Savings:
$10,060
Cost:
-
$7,140 356,975 $2,920 489 - - - - - - - - - - - - - - - - - - - - - - $7,140
356,975
kWh
$2,920
489
kW-months/year
-
-
MMBtu
-
-
MMBtu
-
-
Tgal
-
-
lb
-
-
$
-
-
$
-
-
$
-
-
$
-
-
Tgal
-
-
$
-
-
$
14: 4.652 REPLACE EXISTING EQUIPMENT WITH MORE SUITABLE SUBSTITUTES Savings:
$8,800
Cost:
-
- - - - - - - - - - - - - - $8,800 - - - - - - - - - - - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
MMBtu
-
-
Tgal
-
-
lb
-
-
$
$8,800
-
$
-
-
$
-
-
$
-
-
Tgal
-
-
$
-
-
$
15: 2.2126 LOWER OPERATING PRESSURE OF CONDENSER (STEAM) Savings:
$3,400
Cost:
-
- - - - $3,400 1,613 - - - - - - - - - - - - - - - - - - - - -
-
kWh
-
-
kW-months/year
$3,400
1,613
MMBtu
-
-
MMBtu
-
-
Tgal
-
-
lb
-
-
$
-
-
$
-
-
$
-
-
$
-
-
Tgal
-
-
$
-
-
$
16: 2.4236 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES Savings:
$3,040
Cost:
$1,500
$3,040 152,110 - - - - - - - - - - - - - - - - - - - - - - - - $3,040
152,110
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
MMBtu
-
-
Tgal
-
-
lb
-
-
$
-
-
$
-
-
$
-
-
$
-
-
Tgal
-
-
$
-
-
$
17: 2.7142 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS Savings:
$1,070
Cost:
$3,400
$340 16,999 $140 23 - - - - - - - - $590 - - - - - - - - - - - - - $340
16,999
kWh
$140
23
kW-months/year
-
-
MMBtu
-
-
MMBtu
-
-
Tgal
-
-
lb
$590
-
$
-
-
$
-
-
$
-
-
$
-
-
Tgal
-
-
$
-
-
$
TOTAL RECOMMENDED Savings:
$2,713,841
Cost:
$1,642,300
$41,568 2,047,772 $7,603 1,273 $160,400 75,807 $(-32,000) (-24,960) $41,620 31,565,200 $296,020 37,600,000 $(-114,350) - $219,800 - $224,000 - $207,000 - $45,180 - $1,458,000 - $159,000 - $41,568
2,047,772
kWh
$7,603
1,273
kW-months/year
$160,400
75,807
MMBtu
$(-32,000)
(-24,960)
MMBtu
$41,620
31,565,200
Tgal
$296,020
37,600,000
lb
$(-114,350)
-
$
$219,800
-
$
$224,000
-
$
$207,000
-
$
$45,180
-
Tgal
$1,458,000
-
$
$159,000
-
$
TOTAL IMPLEMENTED Savings:
$167,001
Cost:
$315,400
$9,428 471,571 $4,683 784 - - - - $38,500 29,200,000 - - $72,590 - - - - - - - $41,800 - - - - - $9,428
471,571
kWh
$4,683
784
kW-months/year
-
-
MMBtu
-
-
MMBtu
$38,500
29,200,000
Tgal
-
-
lb
$72,590
-
$
-
-
$
-
-
$
-
-
$
$41,800
-
Tgal
-
-
$
-
-
$
Savings
Cost
$ kWh $ kW-months/year $ MMBtu $ MMBtu $ Tgal $ lb $ $ $ $ $ $ $ $ $ Tgal $ $ $ $
Electricity Usage Electricity Demand Natural Gas Fuel Oil #2 Water Disposal Solid Waste (non-haz) Personnel Changes Administrative Changes Primary Raw Material Ancillary Material Cost Water Consumption Primary Product By-product Production Electricity Usage Electricity Demand Natural Gas Fuel Oil #2 Water Disposal Solid Waste (non-haz) Personnel Changes Administrative Changes Primary Raw Material Ancillary Material Cost Water Consumption Primary Product By-product Production