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IAC Assessment: UD0742
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IAC Assessment: UD0742
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IAC Center University of Dayton
Assessment Year 2006
Principal Product Aluminum Wheels
NAICS 331523 - Nonferrous Metal Die-Casting Foundries
SIC 3363 - Aluminum Die-castings
Sales $100,000,000-$500,000,000
# of Employees 450
Plant Area (Sq.Ft.) 300,000
Annual Production 2,500,000 Pieces
Production Hrs. Annual 8,400
Location (State) OH
Source Yearly Cost Usage Unit Unit Cost
Electricity Usage $1,436,077 46,605,942 kWh $0.03
Electricity Demand $589,925 69,552 kW-months/year $8.48
Natural Gas $4,769,861 470,132 MMBtu $10.15
TOTAL ENERGY COSTS $7,004,454
RECOMMENDED SAVINGS* $1,512,062 *Non-energy impacts
included in savings.
See recommendations below
IMPLEMENTED SAVINGS* $503,276
#|Description Savings
Cost
Status Electricity Usage Electricity Demand Natural Gas Water Disposal Electricity Usage Electricity Demand Natural Gas Water Disposal
$ kWh $ kW-months/year $ MMBtu $ Tgal
01: 2.1321 REPLACE FOSSIL FUEL EQUIPMENT WITH ELECTRICAL EQUIPMENT Savings:
$314,266
Cost:
$2,000,000
$(-361,420) (-7,086,670) - - $675,686 66,570 - - $(-361,420)
(-7,086,670)
kWh
-
-
kW-months/year
$675,686
66,570
MMBtu
-
-
Tgal
02: 2.4224 UPGRADE CONTROLS ON COMPRESSORS Savings:
$198,228
Cost:
$100,000
$198,228 3,886,817 - - - - - - $198,228
3,886,817
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
Tgal
03: 2.2532 USE ONLY AMOUNT OF AIR NECESSARY TO PREVENT EXPLOSION HAZARD Savings:
$185,439
Cost:
-
- - - - $185,439 18,415 - - -
-
kWh
-
-
kW-months/year
$185,439
18,415
MMBtu
-
-
Tgal
04: 2.5194 REDESIGN PROCESS Savings:
$174,377
Cost:
-
- - - - $174,377 17,180 - - -
-
kWh
-
-
kW-months/year
$174,377
17,180
MMBtu
-
-
Tgal
05: 2.2414 USE WASTE HEAT FROM HOT FLUE GASES TO PREHEAT Savings:
$157,269
Cost:
$50,000
- - - - $157,269 15,494 - - -
-
kWh
-
-
kW-months/year
$157,269
15,494
MMBtu
-
-
Tgal
06: 2.2424 USE HEAT IN FLUE GASES TO PREHEAT PRODUCTS OR MATERIALS Savings:
$141,723
Cost:
$50,000
- - - - $141,723 13,963 - - -
-
kWh
-
-
kW-months/year
$141,723
13,963
MMBtu
-
-
Tgal
07: 2.6218 TURN OFF EQUIPMENT WHEN NOT IN USE Savings:
$67,853
Cost:
-
- - - - $67,853 6,685 - - -
-
kWh
-
-
kW-months/year
$67,853
6,685
MMBtu
-
-
Tgal
08: 2.2312 MINIMIZE NON-ESSENTIAL MATERIAL IN HEAT TREATMENT PROCESS Savings:
$67,500
Cost:
$39,000
- - - - $67,500 6,650 - - -
-
kWh
-
-
kW-months/year
$67,500
6,650
MMBtu
-
-
Tgal
09: 2.1113 REDUCE COMBUSTION AIR FLOW TO OPTIMUM Savings:
$55,855
Cost:
$10,000
- - - - $55,855 5,503 - - -
-
kWh
-
-
kW-months/year
$55,855
5,503
MMBtu
-
-
Tgal
10: 2.2515 USE OPTIMUM THICKNESS INSULATION Savings:
$42,660
Cost:
$15,558
- - - - $42,660 4,203 - - -
-
kWh
-
-
kW-months/year
$42,660
4,203
MMBtu
-
-
Tgal
11: 2.7142 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS Savings:
$26,660
Cost:
$122,500
$19,951 511,560 $6,709 732 - - - - $19,951
511,560
kWh
$6,709
732
kW-months/year
-
-
MMBtu
-
-
Tgal
12: 2.2414 USE WASTE HEAT FROM HOT FLUE GASES TO PREHEAT Savings:
$19,230
Cost:
-
- - - - $19,230 1,904 - - -
-
kWh
-
-
kW-months/year
$19,230
1,904
MMBtu
-
-
Tgal
13: 2.4146 USE ADJUSTABLE FREQUENCY DRIVE OR MULTIPLE SPEED MOTORS ON EXISTING SYSTEM Savings:
$18,813
Cost:
$51,160
$14,087 361,200 $4,726 516 - - - - $14,087
361,200
kWh
$4,726
516
kW-months/year
-
-
MMBtu
-
-
Tgal
14: 2.4224 UPGRADE CONTROLS ON COMPRESSORS Savings:
$17,949
Cost:
-
$12,020 226,800 $5,929 648 - - - - $12,020
226,800
kWh
$5,929
648
kW-months/year
-
-
MMBtu
-
-
Tgal
15: 2.4221 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS Savings:
$9,232
Cost:
$5,000
$6,771 173,618 $2,461 264 - - - - $6,771
173,618
kWh
$2,461
264
kW-months/year
-
-
MMBtu
-
-
Tgal
16: 3.1222 REDUCE WATER USE WITH COUNTER CURRENT RINSING Savings:
$7,083
Cost:
-
- - - - - - $7,083 30,241 -
-
kWh
-
-
kW-months/year
-
-
MMBtu
$7,083
30,241
Tgal
17: 2.2515 USE OPTIMUM THICKNESS INSULATION Savings:
$4,031
Cost:
$9,057
- - - - $4,031 397 - - -
-
kWh
-
-
kW-months/year
$4,031
397
MMBtu
-
-
Tgal
18: 2.4111 UTILIZE ENERGY-EFFICIENT BELTS AND OTHER IMPROVED MECHANISMS Savings:
$3,020
Cost:
-
$2,260 57,960 $760 84 - - - - $2,260
57,960
kWh
$760
84
kW-months/year
-
-
MMBtu
-
-
Tgal
19: 2.7142 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS Savings:
$874
Cost:
$867
$655 16,800 $219 24 - - - - $655
16,800
kWh
$219
24
kW-months/year
-
-
MMBtu
-
-
Tgal
TOTAL RECOMMENDED Savings:
$1,512,062
Cost:
$2,453,142
$(-107,448) (-1,851,915) $20,804 2,268 $1,591,623 156,964 $7,083 30,241 $(-107,448)
(-1,851,915)
kWh
$20,804
2,268
kW-months/year
$1,591,623
156,964
MMBtu
$7,083
30,241
Tgal
TOTAL IMPLEMENTED Savings:
$503,276
Cost:
$233,367
$233,114 4,699,937 $13,617 1,488 $249,462 24,587 $7,083 30,241 $233,114
4,699,937
kWh
$13,617
1,488
kW-months/year
$249,462
24,587
MMBtu
$7,083
30,241
Tgal
Savings
Cost
$ kWh $ kW-months/year $ MMBtu $ Tgal
Electricity Usage Electricity Demand Natural Gas Water Disposal Electricity Usage Electricity Demand Natural Gas Water Disposal