IAC Center Lehigh University
Assessment Year 2006
Principal Product Aluminum log billet and extrusions
NAICS 331314 - Secondary Smelting and Alloying of Aluminum
SIC 3341 - Secondary Nonferrous Metals
Sales $69,000,000
# of Employees 200
Plant Area (Sq.Ft.) 150,000
Annual Production 115,000,000 Pounds
Production Hrs. Annual 8,400
Location (State) PA
View Case Study
Source Yearly Cost Usage
Electricity Usage $403,741 9,008,640
Electricity Demand $177,506 17,613
Natural Gas $1,806,565 214,152
TOTAL ENERGY COSTS $2,387,812
RECOMMENDED SAVINGS* $2,061,294 *Non-energy impacts
included in savings.
IMPLEMENTED SAVINGS* $576,811
#|Description Status Electricity Usage Electricity Demand Natural Gas One-time Revenue or Avoided Cost Increase in Production Electricity Usage Electricity Demand Natural Gas One-time Revenue or Avoided Cost Increase in Production
$ kWh $ kW/month $ MMBtu $ $ $ %
01: 4.2110 CONSIDER USE / PURCHASE OF BULK MATERIALS WHERE POSSIBLE Savings:
$1,380,000
Cost:
$3,000,000
- - - - - - - - $1,380,000 - -
-
kWh
-
-
kW/month
-
-
MMBtu
-
-
$
$1,380,000
-
%
02: 2.2442 PREHEAT COMBUSTION AIR WITH WASTE HEAT Savings:
$202,503
Cost:
$95,000
- - - - $202,503 23,993 - - - - -
-
kWh
-
-
kW/month
$202,503
23,993
MMBtu
-
-
$
-
-
%
03: 2.4321 UPGRADE OBSOLETE EQUIPMENT Savings:
$192,971
Cost:
$250,000
- - - - $7,202 853 $13,269 - $172,500 - -
-
kWh
-
-
kW/month
$7,202
853
MMBtu
$13,269
-
$
$172,500
-
%
04: 2.4142 USE ADJUSTABLE FREQUENCY DRIVE TO REPLACE MOTOR-GENERATOR SET Savings:
$73,559
Cost:
$36,000
$44,853 996,724 $28,706 2,848 - - - - - - $44,853
996,724
kWh
$28,706
2,848
kW/month
-
-
MMBtu
-
-
$
-
-
%
05: 2.1133 ADJUST BURNERS FOR EFFICIENT OPERATION Savings:
$66,844
Cost:
$100
- - - - $66,844 7,920 - - - - -
-
kWh
-
-
kW/month
$66,844
7,920
MMBtu
-
-
$
-
-
%
06: 2.1133 ADJUST BURNERS FOR EFFICIENT OPERATION Savings:
$63,349
Cost:
$20,000
- - - - $63,349 7,506 - - - - -
-
kWh
-
-
kW/month
$63,349
7,506
MMBtu
-
-
$
-
-
%
07: 2.1131 REPAIR FAULTY INSULATION IN FURNACES, BOILERS, ETC Savings:
$22,786
Cost:
$30,000
- - - - $22,786 2,700 - - - - -
-
kWh
-
-
kW/month
$22,786
2,700
MMBtu
-
-
$
-
-
%
08: 2.5194 REDESIGN PROCESS Savings:
$19,713
Cost:
$1,000
- - - - $19,713 2,336 - - - - -
-
kWh
-
-
kW/month
$19,713
2,336
MMBtu
-
-
$
-
-
%
09: 2.4226 USE / PURCHASE OPTIMUM SIZED COMPRESSOR Savings:
$12,444
Cost:
$6,000
$8,703 193,395 $3,741 371 - - - - - - $8,703
193,395
kWh
$3,741
371
kW/month
-
-
MMBtu
-
-
$
-
-
%
10: 2.2442 PREHEAT COMBUSTION AIR WITH WASTE HEAT Savings:
$11,211
Cost:
$15,000
- - - - $11,211 1,328 - - - - -
-
kWh
-
-
kW/month
$11,211
1,328
MMBtu
-
-
$
-
-
%
11: 2.1131 REPAIR FAULTY INSULATION IN FURNACES, BOILERS, ETC Savings:
$9,908
Cost:
$7,500
- - - - $9,908 1,174 - - - - -
-
kWh
-
-
kW/month
$9,908
1,174
MMBtu
-
-
$
-
-
%
12: 2.4236 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES Savings:
$6,006
Cost:
$1,000
$4,550 101,118 $1,456 144 - - - - - - $4,550
101,118
kWh
$1,456
144
kW/month
-
-
MMBtu
-
-
$
-
-
%
TOTAL RECOMMENDED Savings:
$2,061,294
Cost:
$3,461,600
$58,106 1,291,237 $33,903 3,363 $403,516 47,810 $13,269 - $1,552,500 - -
-
kWh
-
-
kW/month
-
-
MMBtu
-
-
$
-
-
%
TOTAL IMPLEMENTED Savings:
$576,811
Cost:
$409,600
$13,253 294,513 $5,197 515 $372,592 44,146 $13,269 - $172,500 - -
-
kWh
-
-
kW/month
-
-
MMBtu
-
-
$
-
-
%
$ kWh $ kW/month $ MMBtu $ $ $ %
Electricity Usage Electricity Demand Natural Gas One-time Revenue or Avoided Cost Increase in Production Electricity Usage Electricity Demand Natural Gas One-time Revenue or Avoided Cost Increase in Production
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