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IAC Assessment: UM0193
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IAC Assessment: UM0193
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IAC Center University of Michigan
Assessment Year 2001
Principal Product Aluminum and Magnesium Die Castings
NAICS n/a
SIC 3363 - Aluminum Die-castings
Sales $10,000,000-$50,000,000
# of Employees 135
Plant Area (Sq.Ft.) 80,000
Annual Production 10,000,000 Pieces
Production Hrs. Annual 8,736
Location (State) MI
Source Yearly Cost Usage Unit Unit Cost
Electricity Usage $314,847 8,431,900 kWh $0.04
Electricity Demand $103,949 11,388 kW-months/year $9.13
Electricity Fees $6,258 - $ -
Natural Gas $257,771 43,774 MMBtu $5.89
TOTAL ENERGY COSTS $703,825
RECOMMENDED SAVINGS* $126,930 *Non-energy impacts
included in savings.
See recommendations below
IMPLEMENTED SAVINGS* $72,362
#|Description Savings
Cost
Status Electricity Usage Electricity Demand Natural Gas Other Liquid (non-haz) Personnel Changes Ancillary Material Cost Primary Product Electricity Usage Electricity Demand Natural Gas Other Liquid (non-haz) Personnel Changes Ancillary Material Cost Primary Product
$ kWh $ kW-months/year $ MMBtu $ gal $ $ $ $ $ $
01: 2.7142 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS Savings:
$5,099
Cost:
$12,877
$3,355 89,712 $1,744 175 - - - - - - - - - - $3,355
89,712
kWh
$1,744
175
kW-months/year
-
-
MMBtu
-
-
gal
-
-
$
-
-
$
-
-
$
02: 2.7111 REDUCE ILLUMINATION TO MINIMUM NECESSARY LEVELS Savings:
$1,550
Cost:
$3,000
$1,550 41,440 - - - - - - - - - - - - $1,550
41,440
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
gal
-
-
$
-
-
$
-
-
$
03: 2.4236 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES Savings:
$1,556
Cost:
$675
$1,057 28,338 $499 55 - - - - - - - - - - $1,057
28,338
kWh
$499
55
kW-months/year
-
-
MMBtu
-
-
gal
-
-
$
-
-
$
-
-
$
04: 2.4221 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS Savings:
$1,365
Cost:
$1,000
$928 24,872 $437 48 - - - - - - - - - - $928
24,872
kWh
$437
48
kW-months/year
-
-
MMBtu
-
-
gal
-
-
$
-
-
$
-
-
$
05: 2.4323 USE OPTIMUM SIZE AND CAPACITY EQUIPMENT Savings:
$487
Cost:
$1,000
$487 13,034 - - - - - - - - - - - - $487
13,034
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
gal
-
-
$
-
-
$
-
-
$
06: 2.4324 REPLACE HYDRAULIC / PNEUMATIC EQUIPMENT WITH ELECTRIC EQUIPMENT Savings:
$341
Cost:
$200
$229 6,141 $112 12 - - - - - - - - - - $229
6,141
kWh
$112
12
kW-months/year
-
-
MMBtu
-
-
gal
-
-
$
-
-
$
-
-
$
07: 2.7231 USE RADIANT HEATER FOR SPOT HEATING Savings:
$942
Cost:
$4,500
- - - - $942 160 - - - - - - - - -
-
kWh
-
-
kW-months/year
$942
160
MMBtu
-
-
gal
-
-
$
-
-
$
-
-
$
08: 2.2414 USE WASTE HEAT FROM HOT FLUE GASES TO PREHEAT Savings:
$8,160
Cost:
$2,060
- - - - $8,160 1,386 - - - - - - - - -
-
kWh
-
-
kW-months/year
$8,160
1,386
MMBtu
-
-
gal
-
-
$
-
-
$
-
-
$
09: 3.3122 USE FILTRATION, CENTRIFUGING TO REMOVE CONTAMINANTS Savings:
$9,870
Cost:
$11,000
- - - - - - $9,870 54,000 - - - - - - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
$9,870
54,000
gal
-
-
$
-
-
$
-
-
$
10: 2.5194 REDESIGN PROCESS Savings:
$40,150
Cost:
$2,500
- - - - - - - - - - $40,150 - - - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
gal
-
-
$
$40,150
-
$
-
-
$
11: 4.611 BEGIN A PRACTICE OF PREDICTIVE / PREVENTATIVE MAINTENANCE Savings:
$27,400
Cost:
$1,000
- - - - - - - - - - - - $27,400 - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
gal
-
-
$
-
-
$
$27,400
-
$
12: 4.431 TRAIN OPERATORS FOR MAXIMUM OPERATING EFFICIENCY Savings:
$26,010
Cost:
$1,650
- - - - - - - - $26,010 - - - - - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
gal
$26,010
-
$
-
-
$
-
-
$
13: 4.514 RE-ARRANGE EQUIPMENT LAYOUT TO REDUCE HANDLING COSTS Savings:
$4,000
Cost:
$4,200
- - - - - - - - - - - - $4,000 - -
-
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
gal
-
-
$
-
-
$
$4,000
-
$
TOTAL RECOMMENDED Savings:
$126,930
Cost:
$45,662
$7,606 203,537 $2,792 290 $9,102 1,546 $9,870 54,000 $26,010 - $40,150 - $31,400 - $7,606
203,537
kWh
$2,792
290
kW-months/year
$9,102
1,546
MMBtu
$9,870
54,000
gal
$26,010
-
$
$40,150
-
$
$31,400
-
$
TOTAL IMPLEMENTED Savings:
$72,362
Cost:
$8,375
$3,764 100,791 $1,048 115 - - - - - - $40,150 - $27,400 - $3,764
100,791
kWh
$1,048
115
kW-months/year
-
-
MMBtu
-
-
gal
-
-
$
$40,150
-
$
$27,400
-
$
Savings
Cost
$ kWh $ kW-months/year $ MMBtu $ gal $ $ $ $ $ $
Electricity Usage Electricity Demand Natural Gas Other Liquid (non-haz) Personnel Changes Ancillary Material Cost Primary Product Electricity Usage Electricity Demand Natural Gas Other Liquid (non-haz) Personnel Changes Ancillary Material Cost Primary Product