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IAC Assessment: IP0079
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IAC Assessment: IP0079
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IAC Center Indiana University-Purdue University
Assessment Year 2017
Principal Product Aluminum Castings
NAICS 331524 - Aluminum Foundries (except Die-Casting)
SIC 3365 - Aluminum Foundries
Sales $10,000,000-$50,000,000
# of Employees 140
Plant Area (Sq.Ft.) 168,000
Annual Production 189,099 Pieces
Production Hrs. Annual 4,500
Location (State) IN
Source Yearly Cost Usage Unit Unit Cost
Electricity Usage $481,737 7,255,800 kWh $0.07
Electricity Demand $229,514 20,252 kW-months/year $11.33
Electricity Fees $82,781 - $ -
Natural Gas $341,010 102,958 MMBtu $3.31
TOTAL ENERGY COSTS $1,135,042
RECOMMENDED SAVINGS* $193,216 *Non-energy impacts
included in savings.
See recommendations below
IMPLEMENTED SAVINGS* $97,740
#|Description Savings
Cost
Status Electricity Usage Electricity Demand Electricity Fees Natural Gas Electricity Usage Electricity Demand Electricity Fees Natural Gas
$ kWh $ kW-months/year $ $ $ MMBtu
01: 2.4231 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED Savings:
$5,047
Cost:
$6
$3,471 52,267 $1,576 139 - - - - $3,471
52,267
kWh
$1,576
139
kW-months/year
-
-
$
-
-
MMBtu
02: 2.6211 CONSERVE ENERGY BY EFFICIENT USE OF VENDING MACHINES Savings:
$3,466
Cost:
-
$2,809 42,311 $657 58 - - - - $2,809
42,311
kWh
$657
58
kW-months/year
-
-
$
-
-
MMBtu
03: 2.7221 LOWER TEMPERATURE DURING THE WINTER SEASON AND VICE-VERSA Savings:
$35,073
Cost:
$678
$11,174 168,286 - - - - $23,899 7,220 $11,174
168,286
kWh
-
-
kW-months/year
-
-
$
$23,899
7,220
MMBtu
04: 2.4236 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES Savings:
$6,340
Cost:
$147
$4,357 65,612 $1,983 175 - - - - $4,357
65,612
kWh
$1,983
175
kW-months/year
-
-
$
-
-
MMBtu
05: 2.2514 COVER OPEN TANKS Savings:
$20,504
Cost:
$766
- - - - - - $20,504 6,195 -
-
kWh
-
-
kW-months/year
-
-
$
$20,504
6,195
MMBtu
06: 2.7135 INSTALL OCCUPANCY SENSORS Savings:
$3,135
Cost:
$302
$3,135 47,210 - - - - - - $3,135
47,210
kWh
-
-
kW-months/year
-
-
$
-
-
MMBtu
07: 2.4322 USE OR REPLACE WITH ENERGY EFFICIENT SUBSTITUTES Savings:
$12,652
Cost:
$1,239
$12,652 190,540 - - - - - - $12,652
190,540
kWh
-
-
kW-months/year
-
-
$
-
-
MMBtu
08: 2.4238 DO NOT USE COMPRESSED AIR FOR PERSONAL COOLING Savings:
$742
Cost:
$90
$742 11,170 - - - - - - $742
11,170
kWh
-
-
kW-months/year
-
-
$
-
-
MMBtu
09: 4.812 APPLY FOR INVESTMENT INCENTIVES Savings:
$38,196
Cost:
$5,000
- - - - $38,196 - - - -
-
kWh
-
-
kW-months/year
$38,196
-
$
-
-
MMBtu
10: 2.4146 USE ADJUSTABLE FREQUENCY DRIVE OR MULTIPLE SPEED MOTORS ON EXISTING SYSTEM Savings:
$12,415
Cost:
$9,367
$12,415 186,975 - - - - - - $12,415
186,975
kWh
-
-
kW-months/year
-
-
$
-
-
MMBtu
11: 2.4111 UTILIZE ENERGY-EFFICIENT BELTS AND OTHER IMPROVED MECHANISMS Savings:
$1,761
Cost:
$2,448
$1,210 18,225 $551 49 - - - - $1,210
18,225
kWh
$551
49
kW-months/year
-
-
$
-
-
MMBtu
12: 2.3212 OPTIMIZE PLANT POWER FACTOR Savings:
$23,934
Cost:
$35,575
- - - - $23,934 - - - -
-
kWh
-
-
kW-months/year
$23,934
-
$
-
-
MMBtu
13: 4.812 APPLY FOR INVESTMENT INCENTIVES Savings:
$2,977
Cost:
$5,000
- - - - $2,977 - - - -
-
kWh
-
-
kW-months/year
$2,977
-
$
-
-
MMBtu
14: 2.2414 USE WASTE HEAT FROM HOT FLUE GASES TO PREHEAT Savings:
$10,861
Cost:
$3,300
- - - - - - $10,861 3,281 -
-
kWh
-
-
kW-months/year
-
-
$
$10,861
3,281
MMBtu
15: 2.7142 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS Savings:
$16,112
Cost:
$79,976
$11,074 166,770 $5,038 445 - - - - $11,074
166,770
kWh
$5,038
445
kW-months/year
-
-
$
-
-
MMBtu
TOTAL RECOMMENDED Savings:
$193,216
Cost:
$143,894
$63,039 949,366 $9,805 866 $65,107 - $55,264 16,696 $63,039
949,366
kWh
$9,805
866
kW-months/year
$65,107
-
$
$55,264
16,696
MMBtu
TOTAL IMPLEMENTED Savings:
$97,740
Cost:
$46,584
$8,570 129,049 $3,559 314 $65,107 - $20,504 6,195 $8,570
129,049
kWh
$3,559
314
kW-months/year
$65,107
-
$
$20,504
6,195
MMBtu
Savings
Cost
$ kWh $ kW-months/year $ $ $ MMBtu
Electricity Usage Electricity Demand Electricity Fees Natural Gas Electricity Usage Electricity Demand Electricity Fees Natural Gas