A typical facility could save thousands of dollars annually by detecting and repairing leaks in their compressed air systems.

Compressed air systems can account for 10% to 30% of a facility’s total energy bill.

Leaks typically comprise 25% to 30% demand on the compressor.

Repairing leaks can reduce maintenance, reduce demand for more compressor capacity, reduce energy costs, and increase equipment life.

Compressed air energy costs rely on:

·         Compressor size

·         Compressor type

·         Control type

·         Actual demand for air

·         Hours of operation

Annual Cost of Leaks = Leakage Rate x kW per cfm x Correction Factor x Hours x $/kWh

 

An example taken from the U.S. Department of Energy publication entitled Compressed Air Tip Sheet #3, a chemical plant leak prevention program identified 160 leaks ranging from 1/32” to 1/4" diameter. The total cost savings from repairing these leaks was $57,069.

Cost savings from 1/32” leaks = 100 x 1.46 x 0.61 x 0.18 x 7,000 x 0.05 = $5,611

Cost savings from 1/16” leaks = 50 x 5.72 x 0.61 x 0.18 x 7,000 x 0.05 = $10,991

Cost savings from 1/4” leaks = 10 x 100.9 x 0.61 x 0.18 x 7,000 x 0.05 = $38,776

Source:  Compressed Air Challenge – assume 7,000 annual operating hours, an aggregate electric rate of $0.05 kilowatt-hour (kWh), and compressed air generation requirement of approximately 18 kilowatts (kW)/100 cfm.  

Call now to have us evaluate your system and find out how much money your company could save.