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IAC Assessment: UA3011
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IAC Assessment: UA3011
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IAC Center University of Alabama
Assessment Year 2011
Principal Product Foam Casting Patterns
NAICS 332119 - Metal Crown, Closure, and Other Metal Stamping (except Automotive)
SIC 3463 - Nonferrous Forgings
Sales $1,000,000-$5,000,000
# of Employees 36
Plant Area (Sq.Ft.) 72,000
Annual Production 20,000 Tons
Production Hrs. Annual 6,120
Location (State) AL
Source Yearly Cost Usage Unit Unit Cost
Electricity Usage $127,190 2,351,360 kWh $0.05
Electricity Demand $86,269 6,257 kW-months/year $13.79
Natural Gas $205,744 23,539 MMBtu $8.74
TOTAL ENERGY COSTS $434,957
RECOMMENDED SAVINGS* $97,046 *Non-energy impacts
included in savings.
See recommendations below
IMPLEMENTED SAVINGS* $26,141
#|Description Savings
Cost
Status Electricity Usage Electricity Demand Natural Gas Electricity Usage Electricity Demand Natural Gas
$ kWh $ kW-months/year $ MMBtu
01: 2.7142 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS Savings:
$16,307
Cost:
$26,402
$10,875 201,049 $5,432 394 - - $10,875
201,049
kWh
$5,432
394
kW-months/year
-
-
MMBtu
02: 2.7134 USE PHOTOCELL CONTROLS Savings:
$575
Cost:
$225
$575 10,638 - - - - $575
10,638
kWh
-
-
kW-months/year
-
-
MMBtu
03: 2.4236 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES Savings:
$23,842
Cost:
$5,000
$16,963 313,604 $6,879 499 - - $16,963
313,604
kWh
$6,879
499
kW-months/year
-
-
MMBtu
04: 2.4231 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED Savings:
$5,087
Cost:
$640
$2,964 54,797 $2,123 154 - - $2,964
54,797
kWh
$2,123
154
kW-months/year
-
-
MMBtu
05: 2.4239 ELIMINATE OR REDUCE COMPRESSED AIR USAGE Savings:
$8,304
Cost:
$1,800
$2,929 54,142 $5,375 390 - - $2,929
54,142
kWh
$5,375
390
kW-months/year
-
-
MMBtu
06: 2.2135 REPAIR AND ELIMINATE STEAM LEAKS Savings:
$515
Cost:
$1,030
- - - - $515 59 -
-
kWh
-
-
kW-months/year
$515
59
MMBtu
07: 2.2136 INSTALL / REPAIR INSULATION ON STEAM LINES Savings:
$7,440
Cost:
$4,586
- - - - $7,440 852 -
-
kWh
-
-
kW-months/year
$7,440
852
MMBtu
08: 2.1113 REDUCE COMBUSTION AIR FLOW TO OPTIMUM Savings:
$1,373
Cost:
$320
- - - - $1,373 157 -
-
kWh
-
-
kW-months/year
$1,373
157
MMBtu
09: 2.2414 USE WASTE HEAT FROM HOT FLUE GASES TO PREHEAT Savings:
$13,493
Cost:
$70,000
- - - - $13,493 1,546 -
-
kWh
-
-
kW-months/year
$13,493
1,546
MMBtu
10: 2.7231 USE RADIANT HEATER FOR SPOT HEATING Savings:
$13,650
Cost:
$9,480
- - - - $13,650 1,564 -
-
kWh
-
-
kW-months/year
$13,650
1,564
MMBtu
11: 2.7261 INSTALL TIMERS AND/OR THERMOSTATS Savings:
$366
Cost:
$510
$97 1,800 - - $269 31 $97
1,800
kWh
-
-
kW-months/year
$269
31
MMBtu
12: 2.7261 INSTALL TIMERS AND/OR THERMOSTATS Savings:
$843
Cost:
$50
$173 3,196 - - $670 77 $173
3,196
kWh
-
-
kW-months/year
$670
77
MMBtu
13: 2.2511 INSULATE BARE EQUIPMENT Savings:
$5,251
Cost:
$1,503
$5,251 97,051 - - - - $5,251
97,051
kWh
-
-
kW-months/year
-
-
MMBtu
TOTAL RECOMMENDED Savings:
$97,046
Cost:
$121,546
$39,827 736,277 $19,809 1,437 $37,410 4,286 $39,827
736,277
kWh
$19,809
1,437
kW-months/year
$37,410
4,286
MMBtu
TOTAL IMPLEMENTED Savings:
$26,141
Cost:
$6,815
$17,808 329,238 $6,879 499 $1,454 167 $17,808
329,238
kWh
$6,879
499
kW-months/year
$1,454
167
MMBtu
Savings
Cost
$ kWh $ kW-months/year $ MMBtu
Electricity Usage Electricity Demand Natural Gas Electricity Usage Electricity Demand Natural Gas