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IAC Assessment: OR0494
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DOE MESC
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IAC Assessment: OR0494
IAC Center Oregon State University
Assessment Year 2005
Principal Product Malted Barley
NAICS 311213 - Malt Manufacturing
SIC 2083 - Malt
Sales $50,000,000-$100,000,000
# of Employees 21
Plant Area (Sq.Ft.) 350,000
Annual Production 160,000 Pounds
Production Hrs. Annual 8,760
Location (State) WA
Source Yearly Cost Usage Unit Unit Cost
Electricity Usage $65,078 23,407,670 kWh $0.00
Electricity Demand $27,770 4,408 kW-months/year $6.30
Natural Gas $2,155,106 343,044 MMBtu $6.28
TOTAL ENERGY COSTS $2,306,637
RECOMMENDED SAVINGS* $447,080 *Non-energy impacts
included in savings.
See recommendations below
IMPLEMENTED SAVINGS* $321,100
#|Description Savings
Cost
Status Electricity Usage Electricity Demand Natural Gas Personnel Changes Primary Product Electricity Usage Electricity Demand Natural Gas Personnel Changes Primary Product
$ kWh $ kW-months/year $ MMBtu $ $ $ $
01: 2.2414 USE WASTE HEAT FROM HOT FLUE GASES TO PREHEAT Savings:
$77,000
Cost:
-
- - - - $77,000 11,000 - - - - -
-
kWh
-
-
kW-months/year
$77,000
11,000
MMBtu
-
-
$
-
-
$
02: 2.5123 REDUCE FLUID FLOW RATES Savings:
$63,500
Cost:
-
$6,500 156,000 - - $57,000 8,100 - - - - $6,500
156,000
kWh
-
-
kW-months/year
$57,000
8,100
MMBtu
-
-
$
-
-
$
03: 2.5123 REDUCE FLUID FLOW RATES Savings:
$54,700
Cost:
$630
$9,700 233,000 $4,000 730 $41,000 5,900 - - - - $9,700
233,000
kWh
$4,000
730
kW-months/year
$41,000
5,900
MMBtu
-
-
$
-
-
$
04: 2.5121 REDESIGN FLOW TO MINIMIZE MASS TRANSFER LENGTH Savings:
$36,800
Cost:
$1,400
$36,800 884,900 - - - - - - - - $36,800
884,900
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
$
-
-
$
05: 2.1233 ANALYZE FLUE GAS FOR PROPER AIR/FUEL RATIO Savings:
$55,000
Cost:
$3,100
- - - - $55,000 7,900 - - - - -
-
kWh
-
-
kW-months/year
$55,000
7,900
MMBtu
-
-
$
-
-
$
06: 2.4231 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED Savings:
$5,100
Cost:
-
$4,300 103,000 $800 144 - - - - - - $4,300
103,000
kWh
$800
144
kW-months/year
-
-
MMBtu
-
-
$
-
-
$
07: 2.7124 MAKE A PRACTICE OF TURNING OFF LIGHTS WHEN NOT NEEDED Savings:
$2,400
Cost:
-
$2,000 48,200 $400 66 - - - - - - $2,000
48,200
kWh
$400
66
kW-months/year
-
-
MMBtu
-
-
$
-
-
$
08: 2.4239 ELIMINATE OR REDUCE COMPRESSED AIR USAGE Savings:
$1,100
Cost:
-
$920 22,000 $180 32 - - - - - - $920
22,000
kWh
$180
32
kW-months/year
-
-
MMBtu
-
-
$
-
-
$
09: 2.5123 REDUCE FLUID FLOW RATES Savings:
$2,400
Cost:
-
$5,400 128,800 - - $(-3,000) (-444) - - - - $5,400
128,800
kWh
-
-
kW-months/year
$(-3,000)
(-444)
MMBtu
-
-
$
-
-
$
10: 2.4224 UPGRADE CONTROLS ON COMPRESSORS Savings:
$3,500
Cost:
$2,320
$3,000 70,000 $500 88 - - - - - - $3,000
70,000
kWh
$500
88
kW-months/year
-
-
MMBtu
-
-
$
-
-
$
11: 2.4236 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES Savings:
$6,400
Cost:
$6,500
$5,400 130,000 $1,000 180 - - - - - - $5,400
130,000
kWh
$1,000
180
kW-months/year
-
-
MMBtu
-
-
$
-
-
$
12: 2.4321 UPGRADE OBSOLETE EQUIPMENT Savings:
$1,100
Cost:
$1,300
$900 22,000 $200 30 - - - - - - $900
22,000
kWh
$200
30
kW-months/year
-
-
MMBtu
-
-
$
-
-
$
13: 2.7142 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS Savings:
$22,800
Cost:
$49,400
$10,000 241,700 $1,800 331 - - $11,000 - - - $10,000
241,700
kWh
$1,800
331
kW-months/year
-
-
MMBtu
$11,000
-
$
-
-
$
14: 4.1310 MODIFY PROCESS TO REDUCE MATERIAL USE/COST Savings:
$107,700
Cost:
$340,000
$3,700 90,000 - - $54,000 7,800 - - $50,000 - $3,700
90,000
kWh
-
-
kW-months/year
$54,000
7,800
MMBtu
-
-
$
$50,000
-
$
15: 2.6218 TURN OFF EQUIPMENT WHEN NOT IN USE Savings:
$7,580
Cost:
$19,700
$7,580 91,100 - - - - - - - - $7,580
91,100
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
$
-
-
$
TOTAL RECOMMENDED Savings:
$447,080
Cost:
$424,350
$96,200 2,220,700 $8,880 1,601 $281,000 40,256 $11,000 - $50,000 - $96,200
2,220,700
kWh
$8,880
1,601
kW-months/year
$281,000
40,256
MMBtu
$11,000
-
$
$50,000
-
$
TOTAL IMPLEMENTED Savings:
$321,100
Cost:
$399,630
$47,920 1,152,700 $8,180 1,483 $204,000 29,256 $11,000 - $50,000 - $47,920
1,152,700
kWh
$8,180
1,483
kW-months/year
$204,000
29,256
MMBtu
$11,000
-
$
$50,000
-
$
Savings
Cost
$ kWh $ kW-months/year $ MMBtu $ $ $ $
Electricity Usage Electricity Demand Natural Gas Personnel Changes Primary Product Electricity Usage Electricity Demand Natural Gas Personnel Changes Primary Product