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IAC Assessment: UM0142
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IAC Assessment: UM0142
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IAC Center University of Michigan
Assessment Year 1999
Principal Product Aluminum and Zinc Die Castings
NAICS n/a
SIC 3363 - Aluminum Die-castings
Sales $10,000,000-$50,000,000
# of Employees 100
Plant Area (Sq.Ft.) 90,000
Annual Production 3,500,000 Pounds
Production Hrs. Annual 6,000
Location (State) MI
Source Yearly Cost Usage Unit Unit Cost
Electricity Usage $79,076 4,897,714 kWh $0.02
Electricity Demand $148,365 12,276 kW-months/year $12.09
Electricity Fees $17,701 - $ -
Natural Gas $320,346 92,396 MMBtu $3.47
TOTAL ENERGY COSTS $565,488
RECOMMENDED SAVINGS* $269,213 *Non-energy impacts
included in savings.
See recommendations below
IMPLEMENTED SAVINGS* $19,047
#|Description Savings
Cost
Status Electricity Usage Electricity Demand Electricity Fees Natural Gas Water Consumption Increase in Production Electricity Usage Electricity Demand Electricity Fees Natural Gas Water Consumption Increase in Production
$ kWh $ kW-months/year $ $ $ MMBtu $ Tgal $ %
01: 2.4221 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS Savings:
$416
Cost:
$450
$416 24,619 - - - - - - - - - - $416
24,619
kWh
-
-
kW-months/year
-
-
$
-
-
MMBtu
-
-
Tgal
-
-
%
02: 2.4236 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES Savings:
$4,691
Cost:
$1,250
$1,631 114,009 $3,060 228 - - - - - - - - $1,631
114,009
kWh
$3,060
228
kW-months/year
-
-
$
-
-
MMBtu
-
-
Tgal
-
-
%
03: 2.6218 TURN OFF EQUIPMENT WHEN NOT IN USE Savings:
$39
Cost:
-
$39 2,345 - - - - - - - - - - $39
2,345
kWh
-
-
kW-months/year
-
-
$
-
-
MMBtu
-
-
Tgal
-
-
%
04: 2.1122 RE-SIZE CHARGING OPENINGS OR ADD A MOVABLE DOOR ON EQUIPMENT Savings:
$55,979
Cost:
$38,958
- - - - - - $55,979 16,132 - - - - -
-
kWh
-
-
kW-months/year
-
-
$
$55,979
16,132
MMBtu
-
-
Tgal
-
-
%
05: 2.2414 USE WASTE HEAT FROM HOT FLUE GASES TO PREHEAT Savings:
$44,187
Cost:
$52,200
- - - - - - $44,187 12,734 - - - - -
-
kWh
-
-
kW-months/year
-
-
$
$44,187
12,734
MMBtu
-
-
Tgal
-
-
%
06: 2.3212 OPTIMIZE PLANT POWER FACTOR Savings:
$7,489
Cost:
$10,860
- - - - $7,489 - - - - - - - -
-
kWh
-
-
kW-months/year
$7,489
-
$
-
-
MMBtu
-
-
Tgal
-
-
%
07: 3.4155 METER WASTE WATER Savings:
$6,412
Cost:
$500
- - - - - - - - $6,412 - - - -
-
kWh
-
-
kW-months/year
-
-
$
-
-
MMBtu
$6,412
-
Tgal
-
-
%
08: 4.111 ADD EQUIPMENT/ OPERATORS TO REDUCE PRODUCTION BOTTLENECK Savings:
$150,000
Cost:
$150,000
- - - - - - - - - - $150,000 - -
-
kWh
-
-
kW-months/year
-
-
$
-
-
MMBtu
-
-
Tgal
$150,000
-
%
TOTAL RECOMMENDED Savings:
$269,213
Cost:
$254,218
$2,086 140,973 $3,060 228 $7,489 - $100,166 28,866 $6,412 - $150,000 - $2,086
140,973
kWh
$3,060
228
kW-months/year
$7,489
-
$
$100,166
28,866
MMBtu
$6,412
-
Tgal
$150,000
-
%
TOTAL IMPLEMENTED Savings:
$19,047
Cost:
$13,060
$2,086 140,973 $3,060 228 $7,489 - - - $6,412 - - - $2,086
140,973
kWh
$3,060
228
kW-months/year
$7,489
-
$
-
-
MMBtu
$6,412
-
Tgal
-
-
%
Savings
Cost
$ kWh $ kW-months/year $ $ $ MMBtu $ Tgal $ %
Electricity Usage Electricity Demand Electricity Fees Natural Gas Water Consumption Increase in Production Electricity Usage Electricity Demand Electricity Fees Natural Gas Water Consumption Increase in Production