| Assessment Year | 2003 |
|---|---|
| Principal Product | Grey and Ductile Iron Castings |
| NAICS | 331511: Iron Foundries |
| SIC | 3321: Gray and Ductile Iron Foundries |
| Sales Range | $10 M to 50M |
| # of Employees | 300 |
| Plant Area |
216,000
ft2
|
| Annual Production | 31,000
ton
|
| Production Hrs. Annual | 8,232
hrs
|
| Location (State) | Iowa |
Facility Energy Cost and Usage
| Source | Yearly Cost | Usage | Unit Cost | |
|---|---|---|---|---|
| Electricity Usage | $994,832 | 36,487,200 |
kWh
|
$0.027 |
| Electricity Demand | $663,415 | 116,676 |
kW-mo/yr
|
$5.69 |
| Electricity Fees | $46,254 | - |
|
- |
| Natural Gas | $471,969 | 88,268 |
MMBtu
|
$5.35 |
| TOTAL YEARLY COSTS | - | |||
| RECOMMENDED SAVINGS* | $304,977 |
See individual recommendations below
*Non-energy impacts included in savings.
|
||
| IMPLEMENTED SAVINGS* | $26,366 | |||
Recommendations
| # | Description | Yearly Savings* | Imp'd Cost* | Status | Electricity Usage Savings | Electricity Demand Savings | Natural Gas Savings | Water Disposal Savings | Personnel Changes Savings | Ancillary Material Cost Savings | Water Consumption Savings | Increase in Production Savings |
|---|---|---|---|---|---|---|---|---|---|---|---|---|
| 01 | 2.4236: Eliminate leaks in inert gas and compressed air lines/ valves | $11,482 | $915 |
$8,437
311,332
kWh
|
$3,045
-
kW-mo/yr
|
- | - | - | - | - | - | |
| 02 | 2.4221: Install compressor air intakes in coolest locations | $7,583 | $1,994 |
$5,348
197,361
kWh
|
$2,235
-
kW-mo/yr
|
- | - | - | - | - | - | |
| 03 | 2.4239: Eliminate or reduce compressed air usage | $5,790 | $5,790 |
$2,749
101,430
kWh
|
$3,041
-
kW-mo/yr
|
- | - | - | - | - | - | |
| 04 | 2.4239: Eliminate or reduce compressed air usage | $2,662 | $3,125 |
$2,064
76,146
kWh
|
$598
-
kW-mo/yr
|
- | - | - | - | - | - | |
| 05 | 2.7142: Utilize higher efficiency lamps and/or ballasts | $614 | $586 |
$411
15,204
kWh
|
$203
-
kW-mo/yr
|
- | - | - | - | - | - | |
| 06 | 2.7142: Utilize higher efficiency lamps and/or ballasts | $755 | $1,738 |
$494
18,228
kWh
|
$261
-
kW-mo/yr
|
- | - | - | - | - | - | |
| 07 | 2.7135: Install occupancy sensors | $203 | $599 |
$203
7,489
kWh
|
- | - | - | - | - | - | - | |
| 08 | 2.4133: Use most efficient type of electric motors | $1,450 | $1,754 |
$1,094
27,232
kWh
|
$356
-
kW-mo/yr
|
- | - | - | - | - | - | |
| 09 | 3.4111: Use closed cycle process to minimize waste water production | $34,789 | $29,757 |
$(-850.0)
(-31,360)
kWh
|
$(-414.0)
-
kW-mo/yr
|
- |
$10,032
-
Tgal
|
- | - |
$26,021
-
Tgal
|
- | |
| 10 | 4.131: Modify process to reduce material use/cost | $8,977 | $10,800 | - | - | - |
$8,977
-
Tgal
|
- | - | - | - | |
| 11 | 2.2511: Insulate bare equipment | $1,491 | $3,352 |
$1,003
36,995
kWh
|
$488
-
kW-mo/yr
|
- | - | - | - | - | - | |
| 12 | 4.122: Develop standard procedures to improve internal yields | $200,000 | $200,000 | - | - | - | - | - | - | - | $200,000 | |
| 13 | 3.1191: Change procedures / equipment / operating conditions | $18,530 | $12,000 |
$(-25.0)
(-939)
kWh
|
- |
$(-5,125.0)
-
MMBtu
|
- | $1,000 | $22,680 | - | - | |
| 14 | 2.2514: Cover open tanks | $1,451 | $4,500 |
$1,451
53,543
kWh
|
- | - | - | - | - | - | - | |
| 15 | 4.447: Automate payroll system | $9,200 | $12,500 | - | - | - | - | $9,200 | - | - | - | |
| TOTAL RECOMMENDED | $304,977 | $289,410 |
$22,379
812,661
kWh
|
$9,813
-
kW-mo/yr
|
$(-5,125.0)
-
MMBtu
|
$19,009
-
Tgal
|
$10,200 | $22,680 |
$26,021
-
Tgal
|
$200,000 | ||
| TOTAL IMPLEMENTED | $26,366 | $21,217 |
$12,703
455,631
kWh
|
$4,463
-
kW-mo/yr
|
- | - | $9,200 | - | - | - | ||
| Yearly Savings* | Imp'd Cost* | Electricity Usage Savings | Electricity Demand Savings | Natural Gas Savings | Water Disposal Savings | Personnel Changes Savings | Ancillary Material Cost Savings | Water Consumption Savings | Increase in Production Savings | |||
*Savings and costs are best estimates based on the center's site visit, associated engineering analysis, and typical capital and labor costs