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IAC Assessment: IP0075
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IAC Assessment: IP0075
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IAC Center Indiana University-Purdue University
Assessment Year 2016
Principal Product Steel Forgings
NAICS 332111 - Iron and Steel Forging
SIC 3462 - Iron And Steel Forgings
Sales $50,000,000-$100,000,000
# of Employees 240
Plant Area (Sq.Ft.) 138,000
Annual Production 12,971,000 Pieces
Production Hrs. Annual 3,744
Location (State) IN
Source Yearly Cost Usage Unit Unit Cost
Electricity Usage $2,121,102 39,652,586 kWh $0.05
Electricity Demand $1,335,334 129,896 kW-months/year $10.28
Electricity Fees $226,779 - $ -
Natural Gas $36,193 7,793 MMBtu $4.64
TOTAL ENERGY COSTS $3,719,408
RECOMMENDED SAVINGS* $356,375 *Non-energy impacts
included in savings.
See recommendations below
IMPLEMENTED SAVINGS* $126,132
#|Description Savings
Cost
Status Electricity Usage Electricity Demand Increase in Production Electricity Usage Electricity Demand Increase in Production
$ kWh $ kW-months/year $ %
01: 2.7261 INSTALL TIMERS AND/OR THERMOSTATS Savings:
$2,060
Cost:
$475
$2,060 38,517 - - - - $2,060
38,517
kWh
-
-
kW-months/year
-
-
%
02: 2.4226 USE / PURCHASE OPTIMUM SIZED COMPRESSOR Savings:
$49,318
Cost:
$15,186
$47,137 881,581 $2,181 212 - - $47,137
881,581
kWh
$2,181
212
kW-months/year
-
-
%
03: 2.3212 OPTIMIZE PLANT POWER FACTOR Savings:
$144,133
Cost:
$37,215
- - $144,133 14,021 - - -
-
kWh
$144,133
14,021
kW-months/year
-
-
%
04: 2.4236 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES Savings:
$37,278
Cost:
$17,193
$37,278 678,214 - - - - $37,278
678,214
kWh
-
-
kW-months/year
-
-
%
05: 2.7142 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS Savings:
$88,854
Cost:
$77,418
$7,790 145,641 $4,799 467 $76,265 - $7,790
145,641
kWh
$4,799
467
kW-months/year
$76,265
-
%
06: 2.4111 UTILIZE ENERGY-EFFICIENT BELTS AND OTHER IMPROVED MECHANISMS Savings:
$4,646
Cost:
$9,375
$2,875 53,745 $1,771 173 - - $2,875
53,745
kWh
$1,771
173
kW-months/year
-
-
%
07: 2.4133 USE MOST EFFICIENT TYPE OF ELECTRIC MOTORS Savings:
$30,086
Cost:
$107,214
$18,620 348,098 $11,466 1,115 - - $18,620
348,098
kWh
$11,466
1,115
kW-months/year
-
-
%
TOTAL RECOMMENDED Savings:
$356,375
Cost:
$264,076
$115,760 2,145,796 $164,350 15,988 $76,265 - $115,760
2,145,796
kWh
$164,350
15,988
kW-months/year
$76,265
-
%
TOTAL IMPLEMENTED Savings:
$126,132
Cost:
$94,611
$45,068 823,855 $4,799 467 $76,265 - $45,068
823,855
kWh
$4,799
467
kW-months/year
$76,265
-
%
Savings
Cost
$ kWh $ kW-months/year $ %
Electricity Usage Electricity Demand Increase in Production Electricity Usage Electricity Demand Increase in Production