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IAC Assessment: WV0446
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IAC Assessment: WV0446
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IAC Center West Virginia University
Assessment Year 2012
Principal Product Flavors
NAICS 311930 - Flavoring Syrup and Concentrate Manufacturing
SIC 2087 - Flavoring Extracts And Syrups, Nec
Sales $100,000,000-$500,000,000
# of Employees 200
Plant Area (Sq.Ft.) 110,000
Annual Production 10,000,000 Pounds
Production Hrs. Annual 8,568
Location (State) MD
Source Yearly Cost Usage Unit Unit Cost
Electricity Usage $924,720 9,659,300 kWh $0.10
Electricity Demand $45,961 19,071 kW-months/year $2.41
Natural Gas $414,297 59,431 MMBtu $6.97
TOTAL ENERGY COSTS $1,384,978
RECOMMENDED SAVINGS* $270,250 *Non-energy impacts
included in savings.
See recommendations below
IMPLEMENTED SAVINGS* $39,724
#|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: 2.3413 BURN FOSSIL FUEL TO PRODUCE STEAM TO DRIVE A STEAM TURBINE-GENERATOR AND USE STEAM EXHAUST FOR HEAT Savings:
$147,469
Cost:
$548,000
$200,132 2,090,952 $7,056 2,928 $(-59,719) (-8,568) - - $200,132
2,090,952
kWh
$7,056
2,928
kW-months/year
$(-59,719)
(-8,568)
MMBtu
-
-
$
02: 2.4322 USE OR REPLACE WITH ENERGY EFFICIENT SUBSTITUTES Savings:
$21,144
Cost:
$70,000
$20,423 213,343 $721 299 - - - - $20,423
213,343
kWh
$721
299
kW-months/year
-
-
MMBtu
-
-
$
03: 2.4146 USE ADJUSTABLE FREQUENCY DRIVE OR MULTIPLE SPEED MOTORS ON EXISTING SYSTEM Savings:
$20,208
Cost:
$21,000
$20,208 211,098 - - - - - - $20,208
211,098
kWh
-
-
kW-months/year
-
-
MMBtu
-
-
$
04: 2.4156 ESTABLISH A PREVENTATIVE MAINTENANCE PROGRAM Savings:
$16,273
Cost:
$1,000
$16,597 173,369 $586 243 - - $(-910) - $16,597
173,369
kWh
$586
243
kW-months/year
-
-
MMBtu
$(-910)
-
$
05: 2.4312 IMPROVE LUBRICATION PRACTICES Savings:
$10,748
Cost:
$2,034
$10,382 108,450 $366 152 - - - - $10,382
108,450
kWh
$366
152
kW-months/year
-
-
MMBtu
-
-
$
06: 2.1221 REPLACE OBSOLETE BURNERS WITH MORE EFFICIENT ONES Savings:
$9,842
Cost:
$9,500
- - - - $9,842 1,412 - - -
-
kWh
-
-
kW-months/year
$9,842
1,412
MMBtu
-
-
$
07: 2.2414 USE WASTE HEAT FROM HOT FLUE GASES TO PREHEAT Savings:
$8,197
Cost:
$32,125
- - - - $8,197 1,176 - - -
-
kWh
-
-
kW-months/year
$8,197
1,176
MMBtu
-
-
$
08: 2.1233 ANALYZE FLUE GAS FOR PROPER AIR/FUEL RATIO Savings:
$6,963
Cost:
$2,500
- - - - $7,068 1,014 $(-105) - -
-
kWh
-
-
kW-months/year
$7,068
1,014
MMBtu
$(-105)
-
$
09: 2.4151 DEVELOP A REPAIR/REPLACE POLICY Savings:
$6,712
Cost:
$5,683
$8,511 88,907 $301 125 - - $(-2,100) - $8,511
88,907
kWh
$301
125
kW-months/year
-
-
MMBtu
$(-2,100)
-
$
10: 2.4239 ELIMINATE OR REDUCE COMPRESSED AIR USAGE Savings:
$6,393
Cost:
$423
$6,176 64,517 $217 90 - - - - $6,176
64,517
kWh
$217
90
kW-months/year
-
-
MMBtu
-
-
$
11: 2.2113 REPAIR OR REPLACE STEAM TRAPS Savings:
$3,610
Cost:
$4,438
- - - - $4,182 600 $(-572) - -
-
kWh
-
-
kW-months/year
$4,182
600
MMBtu
$(-572)
-
$
12: 2.4231 REDUCE THE PRESSURE OF COMPRESSED AIR TO THE MINIMUM REQUIRED Savings:
$2,862
Cost:
$1,070
$2,766 28,893 $96 40 - - - - $2,766
28,893
kWh
$96
40
kW-months/year
-
-
MMBtu
-
-
$
13: 2.2136 INSTALL / REPAIR INSULATION ON STEAM LINES Savings:
$2,788
Cost:
$1,351
- - - - $2,788 400 - - -
-
kWh
-
-
kW-months/year
$2,788
400
MMBtu
-
-
$
14: 2.3131 RESCHEDULE PLANT OPERATIONS OR REDUCE LOAD TO AVOID PEAKS Savings:
$2,403
Cost:
$5,700
- - $2,403 997 - - - - -
-
kWh
$2,403
997
kW-months/year
-
-
MMBtu
-
-
$
15: 2.2625 CHILL WATER TO THE HIGHEST TEMPERATURE POSSIBLE Savings:
$2,151
Cost:
$70
$2,079 21,715 $72 30 - - - - $2,079
21,715
kWh
$72
30
kW-months/year
-
-
MMBtu
-
-
$
16: 2.4221 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS Savings:
$1,334
Cost:
$1,625
$1,288 13,456 $46 19 - - - - $1,288
13,456
kWh
$46
19
kW-months/year
-
-
MMBtu
-
-
$
17: 2.4236 ELIMINATE LEAKS IN INERT GAS AND COMPRESSED AIR LINES/ VALVES Savings:
$1,153
Cost:
$475
$1,114 11,633 $39 16 - - - - $1,114
11,633
kWh
$39
16
kW-months/year
-
-
MMBtu
-
-
$
TOTAL RECOMMENDED Savings:
$270,250
Cost:
$706,994
$289,676 3,026,333 $11,903 4,939 $(-27,642) (-3,966) $(-3,687) - $289,676
3,026,333
kWh
$11,903
4,939
kW-months/year
$(-27,642)
(-3,966)
MMBtu
$(-3,687)
-
$
TOTAL IMPLEMENTED Savings:
$39,724
Cost:
$15,236
$31,067 324,517 $1,094 454 $11,250 1,614 $(-3,687) - $31,067
324,517
kWh
$1,094
454
kW-months/year
$11,250
1,614
MMBtu
$(-3,687)
-
$
Savings
Cost
$ kWh $ kW-months/year $ MMBtu $ $
Electricity Usage Electricity Demand Natural Gas Personnel Changes Electricity Usage Electricity Demand Natural Gas Personnel Changes