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IAC Assessment: DS0048
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IAC Assessment: DS0048
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IAC Center South Dakota State
Assessment Year 1996
Principal Product Grey and Ductile Iron Castings
NAICS n/a
SIC 3321 - Gray And Ductile Iron Foundries
Sales $10,000,000-$50,000,000
# of Employees 200
Plant Area (Sq.Ft.) 109,531
Annual Production 10,562 Tons
Production Hrs. Annual 6,864
Location (State) MN
Source Yearly Cost Usage Unit Unit Cost
Electricity Usage $757,434 24,774,912 kWh $0.03
Electricity Demand $254,745 65,172 kW-months/year $3.91
Electricity Fees $81,839 - $ -
Natural Gas $197,021 84,226 MMBtu $2.34
LPG $32,366 6,713 MMBtu $4.82
TOTAL ENERGY COSTS $1,507,469
RECOMMENDED SAVINGS* $110,709 *Non-energy impacts
included in savings.
See recommendations below
IMPLEMENTED SAVINGS* $25,943
#|Description Savings
Cost
Status Electricity Usage Electricity Demand Electricity Fees Natural Gas Water Disposal Solid Waste (non-haz) Administrative Changes Electricity Usage Electricity Demand Electricity Fees Natural Gas Water Disposal Solid Waste (non-haz) Administrative Changes
$ kWh $ kW-months/year $ $ $ MMBtu $ Tgal $ lb $ $
01: 2.3212 OPTIMIZE PLANT POWER FACTOR Savings:
$1,037
Cost:
$1,900
- - - - $1,037 - - - - - - - - - -
-
kWh
-
-
kW-months/year
$1,037
-
$
-
-
MMBtu
-
-
Tgal
-
-
lb
-
-
$
02: 2.7142 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS Savings:
$7,486
Cost:
$18,021
$6,078 198,710 $1,408 360 - - - - - - - - - - $6,078
198,710
kWh
$1,408
360
kW-months/year
-
-
$
-
-
MMBtu
-
-
Tgal
-
-
lb
-
-
$
03: 2.4133 USE MOST EFFICIENT TYPE OF ELECTRIC MOTORS Savings:
$5,919
Cost:
$18,845
$4,181 136,870 $1,738 444 - - - - - - - - - - $4,181
136,870
kWh
$1,738
444
kW-months/year
-
-
$
-
-
MMBtu
-
-
Tgal
-
-
lb
-
-
$
04: 2.4221 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS Savings:
$5,971
Cost:
$750
$5,971 195,193 - - - - - - - - - - - - $5,971
195,193
kWh
-
-
kW-months/year
-
-
$
-
-
MMBtu
-
-
Tgal
-
-
lb
-
-
$
05: 2.4236 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES Savings:
$1,128
Cost:
$250
$1,128 36,928 - - - - - - - - - - - - $1,128
36,928
kWh
-
-
kW-months/year
-
-
$
-
-
MMBtu
-
-
Tgal
-
-
lb
-
-
$
06: 2.2511 INSULATE BARE EQUIPMENT Savings:
$4,640
Cost:
$3,678
- - - - - - $4,640 2,062 - - - - - - -
-
kWh
-
-
kW-months/year
-
-
$
$4,640
2,062
MMBtu
-
-
Tgal
-
-
lb
-
-
$
07: 2.2437 RECOVER WASTE HEAT FROM EQUIPMENT Savings:
$5,733
Cost:
$6,500
- - - - - - $5,733 2,548 - - - - - - -
-
kWh
-
-
kW-months/year
-
-
$
$5,733
2,548
MMBtu
-
-
Tgal
-
-
lb
-
-
$
08: 3.4156 USE FLOW CONTROL VALVES ON EQUIPMENT TO OPTIMIZE WATER USE Savings:
$26,694
Cost:
$160
- - - - - - - - $26,694 6,237,000 - - - - -
-
kWh
-
-
kW-months/year
-
-
$
-
-
MMBtu
$26,694
6,237,000
Tgal
-
-
lb
-
-
$
09: 3.4114 REPLACE CITY WATER WITH RECYCLED WATER VIA COOLING TOWER Savings:
$34,241
Cost:
$40,760
$(-34) (-879) - - - - - - $35,775 5,291,850 - - $(-1,500) - $(-34)
(-879)
kWh
-
-
kW-months/year
-
-
$
-
-
MMBtu
$35,775
5,291,850
Tgal
-
-
lb
$(-1,500)
-
$
10: 3.4116 METER RECYCLED WATER (TO REDUCE SEWER CHARGES) Savings:
$14,032
Cost:
$1,350
- - - - - - - - $14,032 5,312,408 - - - - -
-
kWh
-
-
kW-months/year
-
-
$
-
-
MMBtu
$14,032
5,312,408
Tgal
-
-
lb
-
-
$
11: 3.5315 LEASE / PURCHASE BALER; SELL CARDBOARD TO RECYCLER Savings:
$3,828
Cost:
$4,750
- - - - - - - - - - $3,828 20,800 - - -
-
kWh
-
-
kW-months/year
-
-
$
-
-
MMBtu
-
-
Tgal
$3,828
20,800
lb
-
-
$
TOTAL RECOMMENDED Savings:
$110,709
Cost:
$96,964
$17,324 566,822 $3,146 804 $1,037 - $10,373 4,610 $76,501 16,841,258 $3,828 20,800 $(-1,500) - $17,324
566,822
kWh
$3,146
804
kW-months/year
$1,037
-
$
$10,373
4,610
MMBtu
$76,501
16,841,258
Tgal
$3,828
20,800
lb
$(-1,500)
-
$
TOTAL IMPLEMENTED Savings:
$25,943
Cost:
$49,194
$11,387 372,508 $3,146 804 $1,037 - $10,373 4,610 - - - - - - $11,387
372,508
kWh
$3,146
804
kW-months/year
$1,037
-
$
$10,373
4,610
MMBtu
-
-
Tgal
-
-
lb
-
-
$
Savings
Cost
$ kWh $ kW-months/year $ $ $ MMBtu $ Tgal $ lb $ $
Electricity Usage Electricity Demand Electricity Fees Natural Gas Water Disposal Solid Waste (non-haz) Administrative Changes Electricity Usage Electricity Demand Electricity Fees Natural Gas Water Disposal Solid Waste (non-haz) Administrative Changes