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Nexus Manufacturing
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Rockford, IL (Minerals) Details

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Energy Cost Goals
  • 15% energy cost reduction by 2030
  • 40% energy cost reduction by 2045
  • Blended natural gas cost: $5.37/MMBtu
Progress
  • Baseline Energy Spend (2023): $4,430,250 (825,000 MMBtu)
  • Current Energy Spend: $3,634,783
  • 18.0% Energy Cost Reduction
  • $795,467 of Annual Energy Cost Avoided
  • 8,147 MT of CO2 Emissions Avoided
Energy Spend and Cost Reduction by Month

The HRSG project was commissioned in June. Green shows spend avoided against the dashed baseline.

Cost Reduction by Monitored Equipment
EquipmentRecovered EnergyAnnual EnergyAnnual Cost Avoided
HRSG15.77 MMBtu/hr138,145 MMBtu$741,840
Dust Screw1.14 MMBtu/hr9,986 MMBtu$53,627
Total16.91 MMBtu/hr148,132 MMBtu$795,467
IncludedProjectDeploy DateEnergy Savings (MMBtu/yr)Electricity Increase (kWh/yr)Capital CostCarbon Savings (MT/yr)Annual Cost SavingsROI (years)
Heat Recovery Steam Generator (HRSG) and Condensing Economizer132,00007,260$708,8402.1 years
Kiln Insulation and Partial Electrification144,3754,230,1887,941$487,6411.0 years
Pre-Dryer MVR Concentrator226,87516,785,23012,478$76,92332.5 years
Dryer Exhaust Hot Water Generator33,00001,815$177,2106.8 years
Dryer Electrification with Thermal Storage61,8752,702,2633,403$148,51510.1 years
Full Kiln Electrification with Thermal Storage226,87513,898,45212,478$273,22418.3 years
Total825,000$12,200,00045,375$1,872,3536.5 years