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IAC Assessment: WV0418
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DOE MESC
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IAC Assessment: WV0418
IAC Center West Virginia University
Assessment Year 2010
Principal Product Clay Products
NAICS 327110 - Pottery, Ceramics, and Plumbing Fixture Manufacturing
SIC 3262 - Vitreous China Table & Kitchenware
Sales $100,000,000-$500,000,000
# of Employees 800
Plant Area (Sq.Ft.) 1,595,558
Annual Production 21,600,000 Pieces
Production Hrs. Annual 8,736
Location (State) WV
Source Yearly Cost Usage Unit Unit Cost
Electricity Usage $597,785 20,799,700 kWh $0.03
Electricity Demand $598,676 45,643 kW-months/year $13.12
Natural Gas $3,198,041 472,336 MMBtu $6.77
TOTAL ENERGY COSTS $4,394,502
RECOMMENDED SAVINGS* $517,517 *Non-energy impacts
included in savings.
See recommendations below
IMPLEMENTED SAVINGS* $107,871
#|Description Savings
Cost
Status Electricity Usage Electricity Demand Natural Gas Personnel Changes Electricity Usage Electricity Demand Natural Gas Personnel Changes
$ kWh $ kW-months/year $ MMBtu $ $
01: 2.1233 ANALYZE FLUE GAS FOR PROPER AIR/FUEL RATIO Savings:
$138,747
Cost:
$25,000
- - - - $139,137 20,552 $(-390) - -
-
kWh
-
-
kW-months/year
$139,137
20,552
MMBtu
$(-390)
-
$
02: 2.1221 REPLACE OBSOLETE BURNERS WITH MORE EFFICIENT ONES Savings:
$81,321
Cost:
$88,248
- - - - $81,321 12,012 - - -
-
kWh
-
-
kW-months/year
$81,321
12,012
MMBtu
-
-
$
03: 2.2424 USE HEAT IN FLUE GASES TO PREHEAT PRODUCTS OR MATERIALS Savings:
$69,991
Cost:
$24,464
$(-1,152) (-40,086) $(-2,020) (-154) $73,163 10,807 - - $(-1,152)
(-40,086)
kWh
$(-2,020)
(-154)
kW-months/year
$73,163
10,807
MMBtu
-
-
$
04: 2.2424 USE HEAT IN FLUE GASES TO PREHEAT PRODUCTS OR MATERIALS Savings:
$44,522
Cost:
$17,594
$(-485) (-16,889) $(-420) (-32) $45,427 6,710 - - $(-485)
(-16,889)
kWh
$(-420)
(-32)
kW-months/year
$45,427
6,710
MMBtu
-
-
$
05: 2.2426 USE WASTE HEAT FROM FLUE GASES TO HEAT SPACE CONDITIONING AIR Savings:
$35,021
Cost:
$47,775
$(-2,259) (-78,616) $(-1,417) (-108) $38,697 5,716 - - $(-2,259)
(-78,616)
kWh
$(-1,417)
(-108)
kW-months/year
$38,697
5,716
MMBtu
-
-
$
06: 2.3131 RESCHEDULE PLANT OPERATIONS OR REDUCE LOAD TO AVOID PEAKS Savings:
$33,207
Cost:
$16,040
- - $33,207 2,531 - - - - -
-
kWh
$33,207
2,531
kW-months/year
-
-
MMBtu
-
-
$
07: 2.2511 INSULATE BARE EQUIPMENT Savings:
$22,652
Cost:
$9,549
- - - - $22,652 3,346 - - -
-
kWh
-
-
kW-months/year
$22,652
3,346
MMBtu
-
-
$
08: 2.4157 ESTABLISH A PREDICTIVE MAINTENANCE PROGRAM Savings:
$17,763
Cost:
$2,000
$10,070 350,384 $8,646 659 - - $(-953) - $10,070
350,384
kWh
$8,646
659
kW-months/year
-
-
MMBtu
$(-953)
-
$
09: 2.4151 DEVELOP A REPAIR/REPLACE POLICY Savings:
$15,821
Cost:
$1,715
$8,757 304,682 $7,688 586 - - $(-624) - $8,757
304,682
kWh
$7,688
586
kW-months/year
-
-
MMBtu
$(-624)
-
$
10: 2.7142 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS Savings:
$13,568
Cost:
$19,614
$7,047 245,195 $6,521 497 - - - - $7,047
245,195
kWh
$6,521
497
kW-months/year
-
-
MMBtu
-
-
$
11: 2.7142 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS Savings:
$10,872
Cost:
$35,956
$5,283 183,815 $5,589 426 - - - - $5,283
183,815
kWh
$5,589
426
kW-months/year
-
-
MMBtu
-
-
$
12: 2.4221 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS Savings:
$9,456
Cost:
$5,095
$5,035 175,197 $4,421 337 - - - - $5,035
175,197
kWh
$4,421
337
kW-months/year
-
-
MMBtu
-
-
$
13: 2.2437 RECOVER WASTE HEAT FROM EQUIPMENT Savings:
$6,837
Cost:
$3,870
$(-108) (-3,752) $(-184) (-14) $7,129 1,053 - - $(-108)
(-3,752)
kWh
$(-184)
(-14)
kW-months/year
$7,129
1,053
MMBtu
-
-
$
14: 2.4236 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES Savings:
$6,456
Cost:
$621
$3,438 119,635 $3,018 230 - - - - $3,438
119,635
kWh
$3,018
230
kW-months/year
-
-
MMBtu
-
-
$
15: 2.4111 UTILIZE ENERGY-EFFICIENT BELTS AND OTHER IMPROVED MECHANISMS Savings:
$5,931
Cost:
-
$3,476 120,959 $2,455 187 - - - - $3,476
120,959
kWh
$2,455
187
kW-months/year
-
-
MMBtu
-
-
$
16: 2.4235 REMOVE OR CLOSE OFF UNNEEDED COMPRESSED AIR LINES Savings:
$4,116
Cost:
-
$4,116 143,199 - - - - - - $4,116
143,199
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
$
17: 2.4239 ELIMINATE OR REDUCE COMPRESSED AIR USAGE Savings:
$866
Cost:
$2,717
$459 15,971 $407 31 - - - - $459
15,971
kWh
$407
31
kW-months/year
-
-
MMBtu
-
-
$
18: 2.4312 IMPROVE LUBRICATION PRACTICES Savings:
$370
Cost:
$466
$111 3,857 $259 20 - - - - $111
3,857
kWh
$259
20
kW-months/year
-
-
MMBtu
-
-
$
TOTAL RECOMMENDED Savings:
$517,517
Cost:
$300,724
$43,788 1,523,551 $68,170 5,196 $407,526 60,196 $(-1,967) - $43,788
1,523,551
kWh
$68,170
5,196
kW-months/year
$407,526
60,196
MMBtu
$(-1,967)
-
$
TOTAL IMPLEMENTED Savings:
$107,871
Cost:
$77,733
$47,792 1,662,894 $39,004 2,973 $22,652 3,346 $(-1,577) - $47,792
1,662,894
kWh
$39,004
2,973
kW-months/year
$22,652
3,346
MMBtu
$(-1,577)
-
$
Savings
Cost
$ kWh $ kW-months/year $ MMBtu $ $
Electricity Usage Electricity Demand Natural Gas Personnel Changes Electricity Usage Electricity Demand Natural Gas Personnel Changes