Compressed air provides a safe and reliable source of energy for a wide range of industrial processes. However, with more than 80% of the input energy being lost as heat, air compressors are inherently inefficient. Energy-efficient process design should opt for alternatives wherever possible, and limit compressed air usage to only processes that require it.
Existing compressed air systems can be effectively optimized by taking a systematic approach that reduces demand side air usage and utilizes appropriate technology and controls on the supply side. A properly managed compressed air system can not only save energy, but also reduce maintenance needs, improve production uptime, and lead to more reliable product quality.
Top Five Energy Efficiency Measures for Compressed Air Systems
- Eliminate inappropriate uses of compressed air
- Lower system pressure
- Improve system storage and controls
- Reduce leaks
- Upgrade equipment and maintenance
Explore Tip Sheets and Publications from DOE's Industrial Technologies Office, the Compressed Air System Cheat Sheet, the Compressed Air System Info Card, and the educational Compressed Air Poster to learn more.
Explore additional resources tailored for Better Plants partners and connect with the compressed air subject matter experts below.
Subject Matter Experts
Alex Botts is a Technical Account Manager for the U.S. Department of Energy's Better Plants Program at Oak Ridge National Laboratory (ORNL). She supports industry partners through data analysis, software assistance, and technical expertise, serving as a support engineer for the DOE's MEASUR software suite and acting as the team's compressed air expert. Additionally, she co-leads ORNL's participation in the Industrial Training and Assessment Center (ITAC) Implementation Grant program, leveraging her extensive experience in energy efficiency.
Through her work in the Better Plants Program, Ms. Botts has guided partners to significant energy savings across a diverse range of facilities. As the lead compressed air expert and a columnist for "Compressed Air Best Practices" magazine, she develops and delivers training programs and has contributed to the redevelopment of the AirMaster+ software, which has seen widespread use. Her research output includes several journal papers, technical reports, and presentations for industry conferences and training sessions.
Mr. Botts is dedicated to fostering strong relationships with her partners and actively participates in professional societies to expand her network. Recognized for her collaboration and leadership, she has received several awards for her contributions to energy efficiency in manufacturing. Her commitment to continuous improvement and innovation drives her to continue her efforts within her programs and the advancement of ORNL.
You can reach Alex with compressed-air related questions at bottsam@ornl.gov
Kiran Thirumaran holds a master's degree in Mechnical Engineering from North Caroline State University and has been working on industrial energy efficiency since 2012. He was heavily involved with his university's Industrial Assessment Center where he led his team in performing energy audits of manufacturing plants across the Carolinas and Southern Virginia. His current focus is managing interactions with industrial program partners in the Better Plants Program. He was formerly employed with CLEAResult Consulting Inc, where he served as an energy engineer working closely with various electric and natural gas utilities in the Midwest, helping them achieve their energy reduction targets through the implementation of energy efficiency rebate programs.
You can reach Kiran with compressed air-related questions at thirumarank@ornl.gov