Compressed Air Challenge (CAC) / DOE Industrial Plant Energy Model

Industrial Compressed Air Leak & VFD Energy Auditor

Compressed air is typically the most expensive utility in a manufacturing facility (only 10%–15% electrical efficiency converted into pneumatic work). Model ultrasonic leak repair CFM savings, eliminate fixed-speed unload parasitic losses with Variable Frequency Drive (VFD) retrofits, and capture custom electric utility rebates.

⚙️ 1. Compressor Plant Baseline

🔍 2. Ultrasonic Air Leak Survey Inventory

Include VFD Compressor Retrofit Replaces lead fixed-speed unit with variable speed trim compressor

💰 3. Turnkey Repair CapEx & Utility Rebates

Total Leak Waste
295 CFM
~65 HP Idle Waste
Annual Electricity Saved
$54,890/yr
422,000 kWh / yr Saved
Simple Payback
0.6 Yrs
After $32k Utility Rebate

Plant Air Power Consumption Comparison (kW) 65 kW Continuous Cut

Baseline Compressed Air Load (Leaking & Load/Unload Cycling) 168 kW Demand
Post-Remediation & VFD Modulation 103 kW Demand (38.7% Reduction)

Compressed Air Energy Optimization Budget Schedule

Scope / Line Item Metric Quantity Unit Rate Amount ($)

10-Year Cumulative Operating Savings

$620,000 Net Savings

Ultrasonic leak repair and VFD trim control lowers artificial plant pressure, reduces compressor cycling wear, extends desiccant air dryer service life, and eliminates unnecessary capital purchases of secondary backup compressors.