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IAC Assessment: MA0401
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IAC Assessment: MA0401
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IAC Center University of Massachusetts
Assessment Year 1997
Principal Product Aluminum Alloy
NAICS n/a
SIC 3363 - Aluminum Die-castings
Sales $10,000,000-$50,000,000
# of Employees 118
Plant Area (Sq.Ft.) 260,000
Annual Production 4,500,000 Pounds
Production Hrs. Annual 4,675
Location (State) MA
Source Yearly Cost Usage Unit Unit Cost
Electricity Usage $300,347 7,086,753 kWh $0.04
Electricity Demand $283,623 18,156 kW-months/year $15.62
Natural Gas $157,815 37,695 MMBtu $4.19
Fuel Oil #2 $84,185 15,584 MMBtu $5.40
TOTAL ENERGY COSTS $825,970
RECOMMENDED SAVINGS* $119,952 *Non-energy impacts
included in savings.
See recommendations below
IMPLEMENTED SAVINGS* $18,396
#|Description Savings
Cost
Status Electricity Usage Electricity Demand Natural Gas Solid Waste (haz) Primary Raw Material Water Consumption Primary Product Electricity Usage Electricity Demand Natural Gas Solid Waste (haz) Primary Raw Material Water Consumption Primary Product
$ kWh $ kW-months/year $ MMBtu $ lb $ $ $ Tgal $ $
01: 2.2314 REPLACE HEAT TREATING OVEN WITH MORE EFFICIENT UNIT Savings:
$21,102
Cost:
$70,000
- - - - $21,102 5,172 - - - - - - - - -
-
kWh
-
-
kW-months/year
$21,102
5,172
MMBtu
-
-
lb
-
-
$
-
-
Tgal
-
-
$
02: 2.2514 COVER OPEN TANKS Savings:
$10,768
Cost:
-
$5,992 318,581 - - $4,321 1,059 $455 14,000 - - - - - - $5,992
318,581
kWh
-
-
kW-months/year
$4,321
1,059
MMBtu
$455
14,000
lb
-
-
$
-
-
Tgal
-
-
$
03: 2.2524 AVOID COOLING OF PROCESS STREAMS OR MATERIALS THAT MUST SUBSEQUENTLY BE HEATED Savings:
$1,927
Cost:
-
$1,927 42,204 - - - - - - - - - - - - $1,927
42,204
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
lb
-
-
$
-
-
Tgal
-
-
$
04: 2.4224 UPGRADE CONTROLS ON COMPRESSORS Savings:
$4,875
Cost:
$10,000
$4,519 112,544 $356 23 - - - - - - - - - - $4,519
112,544
kWh
$356
23
kW-months/year
-
-
MMBtu
-
-
lb
-
-
$
-
-
Tgal
-
-
$
05: 2.2524 AVOID COOLING OF PROCESS STREAMS OR MATERIALS THAT MUST SUBSEQUENTLY BE HEATED Savings:
$4,934
Cost:
$15,000
- - - - $3,900 956 $333 8,765 $701 - - - - - -
-
kWh
-
-
kW-months/year
$3,900
956
MMBtu
$333
8,765
lb
$701
-
$
-
-
Tgal
-
-
$
06: 2.4133 USE MOST EFFICIENT TYPE OF ELECTRIC MOTORS Savings:
$826
Cost:
$5,321
$432 9,672 $394 25 - - - - - - - - - - $432
9,672
kWh
$394
25
kW-months/year
-
-
MMBtu
-
-
lb
-
-
$
-
-
Tgal
-
-
$
07: 3.5221 RECYCLE CASTING SAND Savings:
$10,174
Cost:
$30,000
$(-78) (-1,758) - - - - - - $10,252 - - - - - $(-78)
(-1,758)
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
lb
$10,252
-
$
-
-
Tgal
-
-
$
08: 3.4114 REPLACE CITY WATER WITH RECYCLED WATER VIA COOLING TOWER Savings:
$8,331
Cost:
$17,307
$(-615) (-14,068) $(-559) (-36) - - - - - - $9,505 - - - $(-615)
(-14,068)
kWh
$(-559)
(-36)
kW-months/year
-
-
MMBtu
-
-
lb
-
-
$
$9,505
-
Tgal
-
-
$
09: 4.1310 MODIFY PROCESS TO REDUCE MATERIAL USE/COST Savings:
$50,655
Cost:
$5,000
- - - - - - - - - - - - $50,655 - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
lb
-
-
$
-
-
Tgal
$50,655
-
$
10: 4.1220 DEVELOP STANDARD PROCEDURES TO IMPROVE INTERNAL YIELDS Savings:
$2,700
Cost:
$400
- - - - - - - - $2,700 - - - - - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
lb
$2,700
-
$
-
-
Tgal
-
-
$
11: 4.6110 BEGIN A PRACTICE OF PREDICTIVE / PREVENTATIVE MAINTENANCE Savings:
$3,660
Cost:
$2,000
- - - - - - - - - - - - $3,660 - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
lb
-
-
$
-
-
Tgal
$3,660
-
$
TOTAL RECOMMENDED Savings:
$119,952
Cost:
$155,028
$12,177 467,175 $191 12 $29,323 7,187 $788 22,765 $13,653 - $9,505 - $54,315 - $12,177
467,175
kWh
$191
12
kW-months/year
$29,323
7,187
MMBtu
$788
22,765
lb
$13,653
-
$
$9,505
-
Tgal
$54,315
-
$
TOTAL IMPLEMENTED Savings:
$18,396
Cost:
$15,321
$12,870 483,001 $750 48 $4,321 1,059 $455 14,000 - - - - - - $12,870
483,001
kWh
$750
48
kW-months/year
$4,321
1,059
MMBtu
$455
14,000
lb
-
-
$
-
-
Tgal
-
-
$
Savings
Cost
$ kWh $ kW-months/year $ MMBtu $ lb $ $ $ Tgal $ $
Electricity Usage Electricity Demand Natural Gas Solid Waste (haz) Primary Raw Material Water Consumption Primary Product Electricity Usage Electricity Demand Natural Gas Solid Waste (haz) Primary Raw Material Water Consumption Primary Product