Compressed air is one of the most expensive utilities in an industrial facility, and much of it is wasted. Optimizing a compressed air system cuts electricity use, operating costs and greenhouse gas emissions, which makes it one of the most practical first steps in a decarbonization plan. Efficiency Engineering, a Kontrol Technologies company, helps owners find and capture those savings.
Why is compressed air so costly to produce?
Compressed air is often called the fourth utility, but it is far less efficient than electricity, gas or water. Natural Resources Canada notes that it takes about 7 to 8 horsepower of electricity to deliver 1 horsepower of usable compressed air at the point of use, and about four-fifths of a compressor's energy becomes heat. Because many compressors run around the clock, small inefficiencies add up across every shift.
Where is compressed air energy wasted?
Leaks. According to the Compressed Air Challenge, leaks in a poorly maintained system can waste 20 to 30 percent of a compressor's output, while a well-maintained system keeps leakage below 10 percent.
Excess pressure. Natural Resources Canada estimates that lowering operating pressure by just 2 psi reduces energy use by about 1 percent.
Poor controls and sizing. Oversized compressors, multiple units competing with each other, and oversized dryers all use energy without adding production.
Lost heat. Heat from compression is usually vented when it could warm space, water or processes.
How does compressed air optimization support decarbonization?
Every kilowatt-hour saved lowers both operating cost and emissions. Recovering compressor heat can also replace natural gas heating, which is a direct reduction in on-site emissions. That is why Efficiency Engineering's decarbonization roadmap starts with reviewing and reducing energy use before owners consider larger capital investments such as fuel switching or renewable generation.
What does an optimization project involve?
A typical project starts with an energy audit that measures how much air the facility produces and how much it actually uses. From there, the team identifies leaks, right-sizes pressure settings and controls, and evaluates heat recovery. Continuous performance monitoring then verifies the savings and flags new leaks before they become costly.
Who is leading Efficiency Engineering's growth?
Efficiency Engineering has appointed Andrew Smith as Chief Revenue Officer to lead the company's growth in decarbonization, sustainability and industrial efficiency services. Andrew joins a team with more than 30 years of experience in energy savings and GHG reductions that has completed audits and design work for more than 4,000 facilities.
Key takeaways
Compressed air is one of the least efficient and most costly utilities in industrial facilities.
Leaks, excess pressure, poor controls and lost heat are the most common sources of waste.
Reducing compressed air energy use cuts costs and emissions, and supports a broader decarbonization plan.
To review your facility's compressed air and energy performance, contact Efficiency Engineering.