ITAC Assessment: TT0246
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ITAC Assessment: TT0246
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Assessment Year 2021
Principal Product Iron Castings
NAICS 331511: Iron Foundries
SIC 3321: Gray and Ductile Iron Foundries
Sales Range $100
M
to 500
M
# of Employees 1,000
Plant Area 560,000
ft2
Annual Production 700,000
ton
Production Hrs. Annual 6,000
hrs
Location (State) Indiana

Facility Energy Cost and Usage

Source Yearly Cost Usage
Electricity Usage $12,906,073 178,643,870
kWh
Electricity Demand $6,381,360 338,190
kW-mo/yr
Natural Gas $1,715,387 422,781
MMBtu
Other Energy $25,411,363 1,149,208
MMBtu
Waste Disposal Costs
Water Usage $251,311 117,296
Tgal
Water Disposal $121,185 23,789
Tgal
TOTAL YEARLY COSTS $46,786,679
RECOMMENDED SAVINGS* $3,482,377 *Non-energy impacts included in savings.
IMPLEMENTED SAVINGS* $1,506,717

Recommendations

# Description Yearly Savings* Imp'd Cost* Status Electricity Usage Savings Electricity Demand Savings Electricity Fees Savings Other Energy Savings
01 2.2414: Use waste heat from hot flue gases to preheat $1,809,194 $245,104 - - - $1,809,194
-
MMBtu
02 2.7273: Install desiccant humidity control system $955,149 $750,000 $(-30,246.0)
(-418,692)
kWh
$(-15,889.0)
-
kW-mo/yr
- $1,001,284
-
MMBtu
03 2.4323: Use optimum size and capacity equipment $492,629 $66,000 $323,582
4,479,263
kWh
$169,047
-
kW-mo/yr
- -
04 2.4236: Eliminate leaks in inert gas and compressed air lines/ valves $86,933 $48,800 $86,933
1,203,391
kWh
- - -
05 2.4239: Eliminate or reduce compressed air usage $65,738 $130,000 $64,606
894,324
kWh
$1,132
-
kW-mo/yr
- -
06 2.4146: Use adjustable frequency drive or multiple speed motors on existing system $58,939 $31,200 $57,396
794,963
kWh
$1,543
-
kW-mo/yr
- -
07 2.4146: Use adjustable frequency drive or multiple speed motors on existing system $8,067 $33,750 $6,828
94,522
kWh
$1,239
-
kW-mo/yr
- -
08 2.3212: Optimize plant power factor $5,728 $12,000 - - $5,728 -
TOTAL RECOMMENDED $3,482,377 $1,316,854 $509,099
7,047,771
kWh
$157,072
-
kW-mo/yr
$5,728 $2,810,478
-
MMBtu
TOTAL IMPLEMENTED $1,506,717 $847,200 $350,732
4,855,534
kWh
$154,701
-
kW-mo/yr
- $1,001,284
-
MMBtu
Yearly Savings* Imp'd Cost* Electricity Usage Savings Electricity Demand Savings Electricity Fees Savings Other Energy Savings
*Savings and costs are best estimates based on the center's site visit, associated engineering analysis, and typical capital and labor costs