Air Compressor Energy Savings: Finding the Low-Hanging Fruit

A typical 300-hp air compressor costs about $100,000 per year to operate1. At this level of expense it makes sense to invest some time and thought into making sure this “silent” energy hog runs as efficiently as possible.

This white paper reviews some of the many ways to measure compressed air system performance and identify savings opportunities. It also notes costs and some funding sources that readers may find helpful to offset some of them.

Monitor Leaks

Leaks commonly constitute 25% of total compressed air use. If you’re running a three-compressor plant and think you’re on the verge of needing to buy another, hunt down your leaks first. You might be able to avoid a $50,000 capital expense, not to mention the associated project headaches. Walking the lines and listening for leaks is the only way to find individual cracks.

Leaks are among the lowest of the low-hanging fruit on the energy savings tree. Payback time typically is measured in weeks or months instead of years, and repairing them doesn’t require capital funding. That’s easy picking. To flog this metaphor to death, I will add that one must perform this harvest every season for maximum system health.