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IAC logo
IAC Assessment: IP0096
Sponsored by:
EERE AMO
IAC logo
IAC Assessment: IP0096
IAC Center Indiana University-Purdue University
Assessment Year 2018
Principal Product Cast Metal Products
NAICS 331524 - Aluminum Foundries (except Die-Casting)
SIC 3365 - Aluminum Foundries
Sales $50,000,000-$100,000,000
# of Employees 368
Plant Area (Sq.Ft.) 182,522
Annual Production 1,226,494 Units
Production Hrs. Annual 8,568
Location (State) IN
Source Yearly Cost Usage Unit Unit Cost
Electricity Usage $2,114,894 66,774,870 kWh $0.03
Electricity Demand $3,627,241 144,107 kW-months/year $25.17
Electricity Fees $13,608 - $ -
Natural Gas $370,561 71,089 MMBtu $5.21
TOTAL ENERGY COSTS $6,193,513
RECOMMENDED SAVINGS* $408,918 *Non-energy impacts
included in savings.
See recommendations below
IMPLEMENTED SAVINGS* $181,193
#|Description Savings
Cost
Status Electricity Usage Electricity Demand Natural Gas Water Disposal Ancillary Material Cost Electricity Usage Electricity Demand Natural Gas Water Disposal Ancillary Material Cost
$ kWh $ kW-months/year $ MMBtu $ Tgal $ $
01: 2.4111 UTILIZE ENERGY-EFFICIENT BELTS AND OTHER IMPROVED MECHANISMS Savings:
$14,640
Cost:
-
$6,856 216,486 $7,784 309 - - - - - - $6,856
216,486
kWh
$7,784
309
kW-months/year
-
-
MMBtu
-
-
Tgal
-
-
$
02: 2.4323 USE OPTIMUM SIZE AND CAPACITY EQUIPMENT Savings:
$7,096
Cost:
-
$3,396 107,223 $3,700 147 - - - - - - $3,396
107,223
kWh
$3,700
147
kW-months/year
-
-
MMBtu
-
-
Tgal
-
-
$
03: 3.4116 METER RECYCLED WATER (TO REDUCE SEWER CHARGES) Savings:
$26,438
Cost:
$4,500
- - - - - - $26,438 8,185 - - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
$26,438
8,185
Tgal
-
-
$
04: 2.4236 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES Savings:
$34,979
Cost:
$2,680
$15,909 502,326 $19,070 758 - - - - - - $15,909
502,326
kWh
$19,070
758
kW-months/year
-
-
MMBtu
-
-
Tgal
-
-
$
05: 2.4239 ELIMINATE OR REDUCE COMPRESSED AIR USAGE Savings:
$31,331
Cost:
$6
$14,261 450,323 $17,070 678 - - - - - - $14,261
450,323
kWh
$17,070
678
kW-months/year
-
-
MMBtu
-
-
Tgal
-
-
$
06: 2.4239 ELIMINATE OR REDUCE COMPRESSED AIR USAGE Savings:
$14,206
Cost:
$905
$477 15,068 $13,729 546 - - - - - - $477
15,068
kWh
$13,729
546
kW-months/year
-
-
MMBtu
-
-
Tgal
-
-
$
07: 2.4224 UPGRADE CONTROLS ON COMPRESSORS Savings:
$13,560
Cost:
$30,000
$6,168 194,747 $7,392 294 - - - - - - $6,168
194,747
kWh
$7,392
294
kW-months/year
-
-
MMBtu
-
-
Tgal
-
-
$
08: 2.2414 USE WASTE HEAT FROM HOT FLUE GASES TO PREHEAT Savings:
$15,917
Cost:
$12,782
- - - - $15,917 3,055 - - - - -
-
kWh
-
-
kW-months/year
$15,917
3,055
MMBtu
-
-
Tgal
-
-
$
09: 2.2515 USE OPTIMUM THICKNESS INSULATION Savings:
$18,548
Cost:
$984
$9,430 297,488 $9,118 362 - - - - - - $9,430
297,488
kWh
$9,118
362
kW-months/year
-
-
MMBtu
-
-
Tgal
-
-
$
10: 2.7142 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS Savings:
$49,834
Cost:
$68,658
$23,859 753,360 $25,975 1,032 - - - - - - $23,859
753,360
kWh
$25,975
1,032
kW-months/year
-
-
MMBtu
-
-
Tgal
-
-
$
11: 2.7131 ADD AREA LIGHTING SWITCHES Savings:
$1,738
Cost:
$130
$798 25,185 $868 35 - - - - $72 - $798
25,185
kWh
$868
35
kW-months/year
-
-
MMBtu
-
-
Tgal
$72
-
$
12: 2.2492 USE "HEAT WHEEL" OR OTHER HEAT EXCHANGER TO CROSS-EXCHANGE BUILDING EXHAUST AIR WITH MAKE-UP AIR Savings:
$180,631
Cost:
$300,000
- - - - $180,631 34,670 - - - - -
-
kWh
-
-
kW-months/year
$180,631
34,670
MMBtu
-
-
Tgal
-
-
$
TOTAL RECOMMENDED Savings:
$408,918
Cost:
$420,645
$81,154 2,562,206 $104,706 4,161 $196,548 37,725 $26,438 8,185 $72 - $81,154
2,562,206
kWh
$104,706
4,161
kW-months/year
$196,548
37,725
MMBtu
$26,438
8,185
Tgal
$72
-
$
TOTAL IMPLEMENTED Savings:
$181,193
Cost:
$86,145
$71,590 2,260,236 $93,614 3,720 $15,917 3,055 - - $72 - $71,590
2,260,236
kWh
$93,614
3,720
kW-months/year
$15,917
3,055
MMBtu
-
-
Tgal
$72
-
$
Savings
Cost
$ kWh $ kW-months/year $ MMBtu $ Tgal $ $
Electricity Usage Electricity Demand Natural Gas Water Disposal Ancillary Material Cost Electricity Usage Electricity Demand Natural Gas Water Disposal Ancillary Material Cost