| Assessment Year | 2003 |
|---|---|
| Principal Product | Cast iron parts for auto industry |
| NAICS | 331511: Iron Foundries |
| SIC | 3321: Gray and Ductile Iron Foundries |
| Sales Range | $50 M to 100M |
| # of Employees | 688 |
| Plant Area |
440,000
ft2
|
| Annual Production | 188,772,000
lb
|
| Production Hrs. Annual | 6,000
hrs
|
| Location (State) | Virginia |
Facility Energy Cost and Usage
| Source | Yearly Cost | Usage | Unit Cost | |
|---|---|---|---|---|
| Electricity Usage | $1,015,709 | 64,407,700 |
kWh
|
$0.016 |
| Electricity Demand | $1,109,389 | 133,020 |
kW-mo/yr
|
$8.34 |
| Electricity Fees | $54,957 | - |
|
- |
| Natural Gas | $1,182,581 | 164,766 |
MMBtu
|
$7.18 |
| Coal | $1,288,406 | 298,884 |
MMBtu
|
$4.31 |
| TOTAL YEARLY COSTS | - | |||
| RECOMMENDED SAVINGS* | $2,366,596 |
See individual recommendations below
*Non-energy impacts included in savings.
|
||
| IMPLEMENTED SAVINGS* | $1,433,107 | |||
Recommendations
| # | Description | Yearly Savings* | Imp'd Cost* | Status | Electricity Usage Savings | Electricity Demand Savings | Natural Gas Savings | Coal Savings | Personnel Changes Savings | Primary Raw Material Savings | Ancillary Material Cost Savings | One-time Revenue or Avoided Cost Savings | Increase in Production Savings |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| 01 | 4.123: Reduce defects by reducing product tipping | $639,636 | $10,000 | n/a | - | - | - | - | - | - | - | - | $639,636 |
| 02 | 4.126: Install sensors to detect defects | $85,500 | $3,000 | - | - | - | - | $85,500 | - | - | - | - | |
| 03 | 4.454: Modify startup/shutdown times | $1,342,708 | $10,000 |
$103,200
6,000,000
kWh
|
- |
$291,508
-
MMBtu
|
- | $948,000 | - | - | - | - | |
| 04 | 2.4231: Reduce the pressure of compressed air to the minimum required | $10,930 | $20,000 |
$4,455
259,000
kWh
|
$6,475
-
kW-mo/yr
|
- | - | - | - | - | - | - | |
| 05 | 2.2514: Cover open tanks | $14,740 | - | - | - | - |
$17,512
-
MMBtu
|
- | - | $(-2,772.0) | - | - | |
| 06 | 2.4236: Eliminate leaks in inert gas and compressed air lines/ valves | $546 | $1,000 |
$328
19,085
kWh
|
$218
-
kW-mo/yr
|
- | - | - | - | - | - | - | |
| 07 | 2.4236: Eliminate leaks in inert gas and compressed air lines/ valves | $4,899 | $500 |
$10,413
605,426
kWh
|
$7,206
-
kW-mo/yr
|
- | - | $(-6,720.0) | $(-6,000.0) | - | - | - | |
| 08 | 2.7142: Utilize higher efficiency lamps and/or ballasts | $4,127 | $24,350 |
$826
48,000
kWh
|
$1,201
-
kW-mo/yr
|
- | - | - | - | - | $2,100 | - | |
| 09 | 2.2422: Use waste heat from hot flue gases to generate steam | $88,312 | $160,000 | - | - |
$90,312
-
MMBtu
|
- | - | $(-2,000.0) | - | - | - | |
| 10 | 4.424: Improve space comfort conditioning | $175,198 | $307,000 |
$(-2,466.0)
(-143,333)
kWh
|
$(-3,586.0)
-
kW-mo/yr
|
- | - | $187,250 | $(-6,000.0) | - | - | - | |
| TOTAL RECOMMENDED | $2,366,596 | $535,850 |
$116,756
6,788,178
kWh
|
$11,514
-
kW-mo/yr
|
$381,820
-
MMBtu
|
$17,512
-
MMBtu
|
$1,214,030 | $(-14,000.0) | $(-2,772.0) | $2,100 | $639,636 | ||
| TOTAL IMPLEMENTED | $1,433,107 | $13,500 |
$113,613
6,605,426
kWh
|
$7,206
-
kW-mo/yr
|
$291,508
-
MMBtu
|
- | $1,026,780 | $(-6,000.0) | - | - | - | ||
| Yearly Savings* | Imp'd Cost* | Electricity Usage Savings | Electricity Demand Savings | Natural Gas Savings | Coal Savings | Personnel Changes Savings | Primary Raw Material Savings | Ancillary Material Cost Savings | One-time Revenue or Avoided Cost 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