Compressed air is used in a vast majority of bulk solids handling systems to operate equipment such as valves, flow aids and bearing purges. Compressed air is used in almost all industrial facilities and a staggering number of these systems have leaks. The U.S. Department of Energy estimates an average leakage rate of 25%, up to as much as 80%. This means a significant amount of energy and money is being wasted on lost air.

Economics of Compressed Air Leaks

Pneumatic conveying systems typically use compressors as the motive air source, requiring a great amount of air flow. Leaks in these compressed air systems can result in wasted electricity, reduced performance of the overall bulk solids handling system, decreased productivity, and increased maintenance costs. Leaks can also negatively impact equipment life and overall plant productivity.

Compressed air leaks reduce the amount of air flow needed to move product due to decreased pressure at use points. To offset this loss, facilities often turn up the compressor pressure to compensate for the leakage. Of course, increased pressure will also cause more air to flow out of a leak. In other words, higher operating pressure increases the inefficiency and makes a bad problem worse.

Leaks can be Expensive

The annual energy cost for a single leak can be estimated with the following formula:

Annual Cost of Leak = Leakage Rate (Cubic Feet per Minute) x Kilowatt/CFM x Operating Hours x Cost/KH per Kilowatt Hour)

Example:

• A 1/16” leak operating at 100 PSIG will reduce compressed air flow by 6.5 CFM.
• Compressor efficiency is typically 18 kilowatt/100 cubic feet/minute, or 0.18 kW/CFM.
• Average electricity cost per kilowatt hour in late 2022 is $0.1345/kWh
• Assuming compressor operates 8,000 hours/year

Annual Cost of Leak = 6.5 CFM x 0.18 kW/CFM x $0.1345/kWh x 8,000 hours x = $1,259 loss/year for a single small leak!

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