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IAC Assessment: BD0240
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IAC Assessment: BD0240
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IAC Center Bradley University
Assessment Year 2003
Principal Product Steel Wires
NAICS 331222 - Steel Wire Drawing
SIC 3315 - Steel Wire And Related Products
Sales $10,000,000-$50,000,000
# of Employees 90
Plant Area (Sq.Ft.) 94,500
Annual Production 94,350 Tons
Production Hrs. Annual 7,488
Location (State) IL
Source Yearly Cost Usage Unit Unit Cost
Electricity Usage $592,592 16,280,000 kWh $0.04
Electricity Demand $2,685 23,971 kW-months/year $0.11
Natural Gas $554,392 148,406 MMBtu $3.74
TOTAL ENERGY COSTS $1,149,669
RECOMMENDED SAVINGS* $344,869 *Non-energy impacts
included in savings.
See recommendations below
IMPLEMENTED SAVINGS* $42,091
#|Description Savings
Cost
Status Electricity Usage Electricity Demand Natural Gas Water Disposal Solid Waste (haz) Personnel Changes Primary Raw Material Electricity Usage Electricity Demand Natural Gas Water Disposal Solid Waste (haz) Personnel Changes Primary Raw Material
$ kWh $ kW-months/year $ MMBtu $ Tgal $ lb $ $ $ $
01: 2.2442 PREHEAT COMBUSTION AIR WITH WASTE HEAT Savings:
$24,677
Cost:
$4,000
- - - - $24,677 6,598 - - - - - - - - -
-
kWh
-
-
kW-months/year
$24,677
6,598
MMBtu
-
-
Tgal
-
-
lb
-
-
$
-
-
$
02: 2.2136 INSTALL / REPAIR INSULATION ON STEAM LINES Savings:
$16,799
Cost:
$33,005
- - - - $16,799 4,496 - - - - - - - - -
-
kWh
-
-
kW-months/year
$16,799
4,496
MMBtu
-
-
Tgal
-
-
lb
-
-
$
-
-
$
03: 2.7111 REDUCE ILLUMINATION TO MINIMUM NECESSARY LEVELS Savings:
$14,062
Cost:
$750
$13,008 357,357 $64 573 - - - - - - $550 - $440 - $13,008
357,357
kWh
$64
573
kW-months/year
-
-
MMBtu
-
-
Tgal
-
-
lb
$550
-
$
$440
-
$
04: 2.4133 USE MOST EFFICIENT TYPE OF ELECTRIC MOTORS Savings:
$10,092
Cost:
$22,130
$10,024 257,357 $68 588 - - - - - - - - - - $10,024
257,357
kWh
$68
588
kW-months/year
-
-
MMBtu
-
-
Tgal
-
-
lb
-
-
$
-
-
$
05: 2.4221 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS Savings:
$8,436
Cost:
$1,000
$8,395 230,630 $41 370 - - - - - - - - - - $8,395
230,630
kWh
$41
370
kW-months/year
-
-
MMBtu
-
-
Tgal
-
-
lb
-
-
$
-
-
$
06: 2.4239 ELIMINATE OR REDUCE COMPRESSED AIR USAGE Savings:
$7,033
Cost:
$7,500
$7,015 192,718 $18 165 - - - - - - - - - - $7,015
192,718
kWh
$18
165
kW-months/year
-
-
MMBtu
-
-
Tgal
-
-
lb
-
-
$
-
-
$
07: 2.2437 RECOVER WASTE HEAT FROM EQUIPMENT Savings:
$5,367
Cost:
$14,000
- - - - $5,367 1,459 - - - - - - - - -
-
kWh
-
-
kW-months/year
$5,367
1,459
MMBtu
-
-
Tgal
-
-
lb
-
-
$
-
-
$
08: 2.7142 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS Savings:
$4,474
Cost:
$1,250
$3,960 108,780 $19 174 - - - - - - $45 - $450 - $3,960
108,780
kWh
$19
174
kW-months/year
-
-
MMBtu
-
-
Tgal
-
-
lb
$45
-
$
$450
-
$
09: 2.4231 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED Savings:
$4,368
Cost:
-
$4,347 119,434 $21 191 - - - - - - - - - - $4,347
119,434
kWh
$21
191
kW-months/year
-
-
MMBtu
-
-
Tgal
-
-
lb
-
-
$
-
-
$
10: 2.4111 UTILIZE ENERGY-EFFICIENT BELTS AND OTHER IMPROVED MECHANISMS Savings:
$4,111
Cost:
$500
$4,106 112,782 $5 123 - - - - - - - - - - $4,106
112,782
kWh
$5
123
kW-months/year
-
-
MMBtu
-
-
Tgal
-
-
lb
-
-
$
-
-
$
11: 2.7134 USE PHOTOCELL CONTROLS Savings:
$3,929
Cost:
$1,250
$3,407 93,584 $43 385 - - - - - - $45 - $434 - $3,407
93,584
kWh
$43
385
kW-months/year
-
-
MMBtu
-
-
Tgal
-
-
lb
$45
-
$
$434
-
$
12: 2.7142 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS Savings:
$2,951
Cost:
$452
$1,752 48,132 $8 77 - - - - - - $690 - $501 - $1,752
48,132
kWh
$8
77
kW-months/year
-
-
MMBtu
-
-
Tgal
-
-
lb
$690
-
$
$501
-
$
13: 2.7135 INSTALL OCCUPANCY SENSORS Savings:
$1,894
Cost:
$675
$1,424 39,140 $8 76 - - - - - - $231 - $231 - $1,424
39,140
kWh
$8
76
kW-months/year
-
-
MMBtu
-
-
Tgal
-
-
lb
$231
-
$
$231
-
$
14: 3.1161 ELIMINATE/REDUCE AN OPERATION Savings:
$33,260
Cost:
-
- - - - - - - - $33,260 24,653 - - - - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
Tgal
$33,260
24,653
lb
-
-
$
-
-
$
15: 3.4151 MINIMIZE WATER USAGE Savings:
$14,330
Cost:
$400
- - - - - - $14,330 89,500,000 - - - - - - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
$14,330
89,500,000
Tgal
-
-
lb
-
-
$
-
-
$
16: 4.445 INSTALL EQUIPMENT TO MOVE PRODUCT Savings:
$149,760
Cost:
$40,000
- - - - - - - - - - $149,760 - - - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
Tgal
-
-
lb
$149,760
-
$
-
-
$
17: 4.446 AUTOMATE FINISHING PROCESS Savings:
$38,182
Cost:
$54,800
- - - - - - - - - - $38,182 - - - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
Tgal
-
-
lb
$38,182
-
$
-
-
$
18: 4.447 AUTOMATE PAYROLL SYSTEM Savings:
$1,144
Cost:
$2,500
- - - - - - - - - - $1,144 - - - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
Tgal
-
-
lb
$1,144
-
$
-
-
$
TOTAL RECOMMENDED Savings:
$344,869
Cost:
$184,212
$57,438 1,559,914 $295 2,722 $46,843 12,553 $14,330 89,500,000 $33,260 24,653 $190,647 - $2,056 - $57,438
1,559,914
kWh
$295
2,722
kW-months/year
$46,843
12,553
MMBtu
$14,330
89,500,000
Tgal
$33,260
24,653
lb
$190,647
-
$
$2,056
-
$
TOTAL IMPLEMENTED Savings:
$42,091
Cost:
$42,155
$10,422 286,302 $61 550 $16,799 4,496 $14,330 89,500,000 - - $45 - $434 - $10,422
286,302
kWh
$61
550
kW-months/year
$16,799
4,496
MMBtu
$14,330
89,500,000
Tgal
-
-
lb
$45
-
$
$434
-
$
Savings
Cost
$ kWh $ kW-months/year $ MMBtu $ Tgal $ lb $ $ $ $
Electricity Usage Electricity Demand Natural Gas Water Disposal Solid Waste (haz) Personnel Changes Primary Raw Material Electricity Usage Electricity Demand Natural Gas Water Disposal Solid Waste (haz) Personnel Changes Primary Raw Material