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IAC Assessment: WV0417
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DOE MESC
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IAC Assessment: WV0417
IAC Center West Virginia University
Assessment Year 2010
Principal Product Thermoplastics resins
NAICS 325991 - Custom Compounding of Purchased Resins
SIC 3087 - Custom Compound Purchased Resins
Sales $10,000,000-$50,000,000
# of Employees 120
Plant Area (Sq.Ft.) 200,000
Annual Production 25,000,000 Pounds
Production Hrs. Annual 6,000
Location (State) OH
Source Yearly Cost Usage Unit Unit Cost
Electricity Usage $728,201 11,745,600 kWh $0.06
Electricity Demand $215,647 26,956 kW-months/year $8.00
Natural Gas $165,514 14,148 MMBtu $11.70
TOTAL ENERGY COSTS $1,109,362
RECOMMENDED SAVINGS* $91,992 *Non-energy impacts
included in savings.
See recommendations below
IMPLEMENTED SAVINGS* $49,139
#|Description Savings
Cost
Status Electricity Usage Electricity Demand Natural Gas Personnel Changes Administrative Changes Electricity Usage Electricity Demand Natural Gas Personnel Changes Administrative Changes
$ kWh $ kW-months/year $ MMBtu $ $ $ $
01: 2.6124 ESTABLISH EQUIPMENT MAINTENANCE SCHEDULE Savings:
$34,786
Cost:
$29,500
$7,286 117,493 - - - - - - $27,500 - $7,286
117,493
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
$
$27,500
-
$
02: 2.7142 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS Savings:
$22,811
Cost:
$46,085
$18,131 292,433 $4,680 585 - - - - - - $18,131
292,433
kWh
$4,680
585
kW-months/year
-
-
MMBtu
-
-
$
-
-
$
03: 2.2511 INSULATE BARE EQUIPMENT Savings:
$10,416
Cost:
$8,214
$8,175 131,850 $2,112 264 $129 11 - - - - $8,175
131,850
kWh
$2,112
264
kW-months/year
$129
11
MMBtu
-
-
$
-
-
$
04: 2.4151 DEVELOP A REPAIR/REPLACE POLICY Savings:
$6,314
Cost:
$1,220
$5,898 95,134 $1,496 187 - - $(-1,080) - - - $5,898
95,134
kWh
$1,496
187
kW-months/year
-
-
MMBtu
$(-1,080)
-
$
-
-
$
05: 2.4157 ESTABLISH A PREDICTIVE MAINTENANCE PROGRAM Savings:
$4,608
Cost:
$3,000
$4,424 71,351 $1,144 143 - - $(-960) - - - $4,424
71,351
kWh
$1,144
143
kW-months/year
-
-
MMBtu
$(-960)
-
$
-
-
$
06: 2.2628 UTILIZE A LESS EXPENSIVE COOLING METHOD Savings:
$3,780
Cost:
$4,485
$2,988 48,200 $792 99 - - - - - - $2,988
48,200
kWh
$792
99
kW-months/year
-
-
MMBtu
-
-
$
-
-
$
07: 2.2414 USE WASTE HEAT FROM HOT FLUE GASES TO PREHEAT Savings:
$3,311
Cost:
$7,750
- - - - $3,311 283 - - - - -
-
kWh
-
-
kW-months/year
$3,311
283
MMBtu
-
-
$
-
-
$
08: 2.4236 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES Savings:
$2,656
Cost:
$1,188
$2,094 33,776 $562 48 - - - - - - $2,094
33,776
kWh
$562
48
kW-months/year
-
-
MMBtu
-
-
$
-
-
$
09: 2.1233 ANALYZE FLUE GAS FOR PROPER AIR/FUEL RATIO Savings:
$2,334
Cost:
$1,500
- - - - $2,469 211 $(-135) - - - -
-
kWh
-
-
kW-months/year
$2,469
211
MMBtu
$(-135)
-
$
-
-
$
10: 2.4221 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS Savings:
$976
Cost:
$1,290
$824 13,288 $152 19 - - - - - - $824
13,288
kWh
$152
19
kW-months/year
-
-
MMBtu
-
-
$
-
-
$
TOTAL RECOMMENDED Savings:
$91,992
Cost:
$104,232
$49,820 803,525 $10,938 1,345 $5,909 505 $(-2,175) - $27,500 - $49,820
803,525
kWh
$10,938
1,345
kW-months/year
$5,909
505
MMBtu
$(-2,175)
-
$
$27,500
-
$
TOTAL IMPLEMENTED Savings:
$49,139
Cost:
$61,207
$38,722 624,544 $9,994 1,227 $2,598 222 $(-2,175) - - - $38,722
624,544
kWh
$9,994
1,227
kW-months/year
$2,598
222
MMBtu
$(-2,175)
-
$
-
-
$
Savings
Cost
$ kWh $ kW-months/year $ MMBtu $ $ $ $
Electricity Usage Electricity Demand Natural Gas Personnel Changes Administrative Changes Electricity Usage Electricity Demand Natural Gas Personnel Changes Administrative Changes