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IAC Assessment: DS0141
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IAC Assessment: DS0141
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IAC Center South Dakota State
Assessment Year 1999
Principal Product Aluminum Die Castings
NAICS n/a
SIC 3363 - Aluminum Die-castings
Sales $10,000,000-$50,000,000
# of Employees 155
Plant Area (Sq.Ft.) 80,300
Annual Production 12,000,000 Pieces
Production Hrs. Annual 7,488
Location (State) MN
Source Yearly Cost Usage Unit Unit Cost
Electricity Usage $202,891 5,992,087 kWh $0.03
Electricity Demand $103,041 14,232 kW-months/year $7.24
Electricity Fees $5,261 - $ -
Natural Gas $288,514 99,091 MMBtu $2.91
LPG $10,842 2,934 MMBtu $3.70
TOTAL ENERGY COSTS $665,946
RECOMMENDED SAVINGS* $540,172 *Non-energy impacts
included in savings.
See recommendations below
IMPLEMENTED SAVINGS* $36,787
#|Description Savings
Cost
Status Electricity Usage Electricity Demand Electricity Fees Natural Gas Water Disposal Administrative Changes Ancillary Material Cost Electricity Usage Electricity Demand Electricity Fees Natural Gas Water Disposal Administrative Changes Ancillary Material Cost
$ kWh $ kW-months/year $ $ $ MMBtu $ Tgal $ $ $ $
01: 2.2442 PREHEAT COMBUSTION AIR WITH WASTE HEAT Savings:
$10,285
Cost:
$24,040
- - - - - - $10,285 3,534 - - - - - - -
-
kWh
-
-
kW-months/year
-
-
$
$10,285
3,534
MMBtu
-
-
Tgal
-
-
$
-
-
$
02: 2.3212 OPTIMIZE PLANT POWER FACTOR Savings:
$4,260
Cost:
$4,500
- - - - $4,260 - - - - - - - - - -
-
kWh
-
-
kW-months/year
$4,260
-
$
-
-
MMBtu
-
-
Tgal
-
-
$
-
-
$
03: 2.4221 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS Savings:
$1,031
Cost:
$700
$760 22,274 $271 36 - - - - - - - - - - $760
22,274
kWh
$271
36
kW-months/year
-
-
$
-
-
MMBtu
-
-
Tgal
-
-
$
-
-
$
04: 2.4236 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES Savings:
$4,348
Cost:
$900
$3,208 94,373 $1,140 151 - - - - - - - - - - $3,208
94,373
kWh
$1,140
151
kW-months/year
-
-
$
-
-
MMBtu
-
-
Tgal
-
-
$
-
-
$
05: 2.4321 UPGRADE OBSOLETE EQUIPMENT Savings:
$13,679
Cost:
$32,000
- - - - - - $13,679 4,701 - - - - - - -
-
kWh
-
-
kW-months/year
-
-
$
$13,679
4,701
MMBtu
-
-
Tgal
-
-
$
-
-
$
06: 3.4116 METER RECYCLED WATER (TO REDUCE SEWER CHARGES) Savings:
$3,184
Cost:
$1,200
- - - - - - - - $3,184 1,061,424 - - - - -
-
kWh
-
-
kW-months/year
-
-
$
-
-
MMBtu
$3,184
1,061,424
Tgal
-
-
$
-
-
$
07: 3.1191 CHANGE PROCEDURES / EQUIPMENT / OPERATING CONDITIONS Savings:
$77,215
Cost:
-
- - - - - - - - - - - - $77,215 - -
-
kWh
-
-
kW-months/year
-
-
$
-
-
MMBtu
-
-
Tgal
-
-
$
$77,215
-
$
08: 3.5316 CONTRACT A WOOD PALLET RECYCLING COMPANY Savings:
$6,612
Cost:
$400
- - - - - - - - - - $6,612 - - - -
-
kWh
-
-
kW-months/year
-
-
$
-
-
MMBtu
-
-
Tgal
$6,612
-
$
-
-
$
09: 4.2110 CONSIDER USE / PURCHASE OF BULK MATERIALS WHERE POSSIBLE Savings:
$3,240
Cost:
$1,000
- - - - - - - - - - $3,240 - - - -
-
kWh
-
-
kW-months/year
-
-
$
-
-
MMBtu
-
-
Tgal
$3,240
-
$
-
-
$
10: 3.2176 INCREASE USE OF AUTOMATION Savings:
$416,318
Cost:
$440,000
- - - - - - - - - - $416,318 - - - -
-
kWh
-
-
kW-months/year
-
-
$
-
-
MMBtu
-
-
Tgal
$416,318
-
$
-
-
$
TOTAL RECOMMENDED Savings:
$540,172
Cost:
$504,740
$3,968 116,647 $1,411 187 $4,260 - $23,964 8,235 $3,184 1,061,424 $426,170 - $77,215 - $3,968
116,647
kWh
$1,411
187
kW-months/year
$4,260
-
$
$23,964
8,235
MMBtu
$3,184
1,061,424
Tgal
$426,170
-
$
$77,215
-
$
TOTAL IMPLEMENTED Savings:
$36,787
Cost:
$63,340
$3,968 116,647 $1,411 187 $4,260 - $23,964 8,235 $3,184 1,061,424 - - - - $3,968
116,647
kWh
$1,411
187
kW-months/year
$4,260
-
$
$23,964
8,235
MMBtu
$3,184
1,061,424
Tgal
-
-
$
-
-
$
Savings
Cost
$ kWh $ kW-months/year $ $ $ MMBtu $ Tgal $ $ $ $
Electricity Usage Electricity Demand Electricity Fees Natural Gas Water Disposal Administrative Changes Ancillary Material Cost Electricity Usage Electricity Demand Electricity Fees Natural Gas Water Disposal Administrative Changes Ancillary Material Cost