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IAC Assessment: AM0412
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IAC Assessment: AM0412
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IAC Center Texas A&M, College Station
Assessment Year 2002
Principal Product Industrial organic chemical processing and distilling
NAICS n/a
SIC 2819 - Industrial Inorganic Chemicals, Nec
Sales $10,000,000-$50,000,000
# of Employees 135
Plant Area (Sq.Ft.) 0
Annual Production 500,000,000 Pounds
Production Hrs. Annual 8,760
Location (State) TX
Source Yearly Cost Usage Unit Unit Cost
Electricity Usage $1,034,627 22,010,765 kWh $0.05
Electricity Demand $235,099 38,076 kW-months/year $6.17
Electricity Fees $5,880 - $ -
Natural Gas $3,598,649 896,736 MMBtu $4.01
TOTAL ENERGY COSTS $4,874,255
RECOMMENDED SAVINGS* $1,770,175 *Non-energy impacts
included in savings.
See recommendations below
IMPLEMENTED SAVINGS* $337,765
#|Description Savings
Cost
Status Electricity Usage Electricity Demand Natural Gas Solid Waste (non-haz) Personnel Changes Ancillary Material Cost Water Consumption Electricity Usage Electricity Demand Natural Gas Solid Waste (non-haz) Personnel Changes Ancillary Material Cost Water Consumption
$ kWh $ kW-months/year $ MMBtu $ lb $ $ $ $ $ Tgal
01: 2.2121 INCREASE AMOUNT OF CONDENSATE RETURNED Savings:
$596,000
Cost:
$117,000
- - - - - - - - - - - - $596,000 - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
lb
-
-
$
-
-
$
$596,000
-
Tgal
02: 4.652 REPLACE EXISTING EQUIPMENT WITH MORE SUITABLE SUBSTITUTES Savings:
$536,220
Cost:
$248,400
- - - - - - - - $536,220 - - - - - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
lb
$536,220
-
$
-
-
$
-
-
Tgal
03: 2.3321 USE STEAM PRESSURE REDUCTION TO GENERATE POWER Savings:
$144,000
Cost:
$600,000
$120,000 2,770,000 $24,000 3,800 - - - - - - - - - - $120,000
2,770,000
kWh
$24,000
3,800
kW-months/year
-
-
MMBtu
-
-
lb
-
-
$
-
-
$
-
-
Tgal
04: 2.4236 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES Savings:
$140,200
Cost:
$5,100
- - - - - - - - - - $140,200 - - - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
lb
-
-
$
$140,200
-
$
-
-
Tgal
05: 2.3321 USE STEAM PRESSURE REDUCTION TO GENERATE POWER Savings:
$106,000
Cost:
$140,000
$88,000 2,000,000 $18,000 2,800 - - - - - - - - - - $88,000
2,000,000
kWh
$18,000
2,800
kW-months/year
-
-
MMBtu
-
-
lb
-
-
$
-
-
$
-
-
Tgal
06: 2.2135 REPAIR AND ELIMINATE STEAM LEAKS Savings:
$104,625
Cost:
$11,800
- - - - $104,625 21,050 - - - - - - - - -
-
kWh
-
-
kW-months/year
$104,625
21,050
MMBtu
-
-
lb
-
-
$
-
-
$
-
-
Tgal
07: 2.4133 USE MOST EFFICIENT TYPE OF ELECTRIC MOTORS Savings:
$60,150
Cost:
$202,680
$43,050 1,001,610 $17,100 1,400 - - - - - - - - - - $43,050
1,001,610
kWh
$17,100
1,400
kW-months/year
-
-
MMBtu
-
-
lb
-
-
$
-
-
$
-
-
Tgal
08: 2.2161 OPTIMIZE OPERATION OF MULTI-STAGE VACUUM STEAM JETS Savings:
$32,540
Cost:
$117,000
$(-3,340) (-77,770) $(-1,890) (-155) $17,170 3,460 - - - - - - $20,600 - $(-3,340)
(-77,770)
kWh
$(-1,890)
(-155)
kW-months/year
$17,170
3,460
MMBtu
-
-
lb
-
-
$
-
-
$
$20,600
-
Tgal
09: 2.2113 REPAIR OR REPLACE STEAM TRAPS Savings:
$24,450
Cost:
$1,375
- - - - $24,450 4,920 - - - - - - - - -
-
kWh
-
-
kW-months/year
$24,450
4,920
MMBtu
-
-
lb
-
-
$
-
-
$
-
-
Tgal
10: 2.4314 USE SYNTHETIC LUBRICANT Savings:
$8,430
Cost:
-
$6,030 140,235 $2,400 196 - - - - - - - - - - $6,030
140,235
kWh
$2,400
196
kW-months/year
-
-
MMBtu
-
-
lb
-
-
$
-
-
$
-
-
Tgal
11: 2.4146 USE ADJUSTABLE FREQUENCY DRIVE OR MULTIPLE SPEED MOTORS ON EXISTING SYSTEM Savings:
$7,100
Cost:
$8,600
$7,100 166,000 - - - - - - - - - - - - $7,100
166,000
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
lb
-
-
$
-
-
$
-
-
Tgal
12: 2.3212 OPTIMIZE PLANT POWER FACTOR Savings:
$6,560
Cost:
-
- - $6,560 537 - - - - - - - - - - -
-
kWh
$6,560
537
kW-months/year
-
-
MMBtu
-
-
lb
-
-
$
-
-
$
-
-
Tgal
13: 3.7132 REUSE RAGS UNTIL COMPLETELY SOILED Savings:
$2,120
Cost:
-
- - - - - - $2,120 1,500 - - - - - - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
$2,120
1,500
lb
-
-
$
-
-
$
-
-
Tgal
14: 2.7124 MAKE A PRACTICE OF TURNING OFF LIGHTS WHEN NOT NEEDED Savings:
$1,000
Cost:
-
$1,000 23,460 - - - - - - - - - - - - $1,000
23,460
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
lb
-
-
$
-
-
$
-
-
Tgal
15: 2.7121 UTILIZE DAYLIGHT WHENEVER POSSIBLE IN LIEU OF ARTIFICIAL LIGHT Savings:
$780
Cost:
-
$780 18,200 - - - - - - - - - - - - $780
18,200
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
lb
-
-
$
-
-
$
-
-
Tgal
TOTAL RECOMMENDED Savings:
$1,770,175
Cost:
$1,451,955
$262,620 6,041,735 $66,170 8,578 $146,245 29,430 $2,120 1,500 $536,220 - $140,200 - $616,600 - $262,620
6,041,735
kWh
$66,170
8,578
kW-months/year
$146,245
29,430
MMBtu
$2,120
1,500
lb
$536,220
-
$
$140,200
-
$
$616,600
-
Tgal
TOTAL IMPLEMENTED Savings:
$337,765
Cost:
$220,955
$44,830 1,043,270 $23,660 1,937 $129,075 25,970 - - - - $140,200 - - - $44,830
1,043,270
kWh
$23,660
1,937
kW-months/year
$129,075
25,970
MMBtu
-
-
lb
-
-
$
$140,200
-
$
-
-
Tgal
Savings
Cost
$ kWh $ kW-months/year $ MMBtu $ lb $ $ $ $ $ Tgal
Electricity Usage Electricity Demand Natural Gas Solid Waste (non-haz) Personnel Changes Ancillary Material Cost Water Consumption Electricity Usage Electricity Demand Natural Gas Solid Waste (non-haz) Personnel Changes Ancillary Material Cost Water Consumption