Compressed Air Leak Cost and CO2 Calculator
Leaks commonly waste a large share of a plant's compressed air output, and every cubic foot costs electricity. This calculator turns a leak survey count into energy, money and CO2e so the case for repair is clear.
Your numbers
Approximate flow through a sharp orifice at 100 psig, the form used in many compressed air guides.
About 18 to 22 kW per 100 cfm is typical for a loaded rotary screw compressor.
Use your location-based factor.
Your results
Estimates only. Real flow depends on pressure, leak geometry and compressor control. Use an ultrasonic leak survey and a flow meter for audit-grade figures.
Annual cost of leaks vs number of leaks
Sweeps Number of leaks found from 0 to 100, holding your other inputs fixed.
Tie energy projects to ERP data
Optional: ask how work orders and meter data can show the real savings.
Optional. The tool and every export work without this. No spam.
How to use the calculator
Walk the plant with an ultrasonic leak detector and tag each leak. Group them by approximate size and run the calculator once per group, or use an average. Enter your operating hours, your compressor's specific power and your electricity price. The result shows total lost flow, the electricity it consumes, the annual cost and the carbon emissions. Then set the share you expect to repair to see the savings.
- Use hours the compressors actually run loaded
- Check specific power on the compressor data sheet or from a power log
- Use a market or location based emission factor consistently
The formula
Lost flow in cfm is the leak flow times the number of leaks. Electricity is lost flow times specific power in kW per cfm times operating hours. Cost is kWh times tariff, and CO2e in tonnes is kWh times the grid factor divided by 1,000. Orifice flow rises roughly with the square of the diameter, so one large leak can outweigh many small ones.
Reading the result
If your total lost flow is a large fraction of compressor capacity, you may be running an extra compressor just to feed leaks. After repairs, check whether a compressor can be switched off or the pressure setpoint lowered, which saves further energy. Repeat the survey every six to twelve months, since leaks return.
Common mistakes
Estimating leak size by eye, mixing metric and imperial units, and counting savings without turning a compressor off. Savings only appear on the bill when the supply side changes.
Frequently Asked Questions
What is a typical share of air lost to leaks?
Guides from energy agencies commonly cite 20 to 30 percent of compressor output in poorly maintained systems, and much less in well managed plants. Your own survey and flow measurement will give the real figure for your site.
How do I find the specific power of my compressor?
Look at the data sheet for kW per 100 cfm at your operating pressure, or divide measured power by measured flow. Part load operation raises the figure, so use a measured value when you can.
Does lowering pressure reduce leak flow?
Yes. Leak flow falls with pressure, and compressor power falls too, roughly one percent per 2 psi for many machines. Do not drop pressure below what the tools need, and repair leaks first.
Can I use this for scope 2 reporting?
It gives an estimate of the electricity wasted, which is already part of your scope 2 total. Use it to show the saving from a project, not as an extra line in the inventory.
If you want leak survey results, energy meter data and work orders tied together in your ERP, we can help set that up.
Related Tools
Refrigerant Leak Rate and Repair Log Worksheet
Calculate each appliance's annual leak rate from charge and top-up amounts, and the CO2e of refrigerant lost for your emissions inventory.
Safety & WorkforceEnvironmental Aspects and Impacts Register Worksheet
Score each activity's environmental aspect for severity, frequency and control, and see which ones rank as significant.
Discrete ManufacturingEnergy Efficiency Savings Calculator
Estimate monthly and annual energy savings, net capex, and payback period for common manufacturing energy efficiency measures.
Compliance & ContractsEnvironmental Compliance Obligations Register Worksheet
Track every permit, regulation and customer requirement with owner, frequency and next due date, and see overdue items at a glance.
More Safety & Workforce tools
See all- Hazard Identification and Risk Ranking Worksheet
- Plant HR and Labor KPI Definitions Reference
- Shift Work Fatigue Risk Assessment
- New Operator First Week Onboarding Checklist
- Production Supervisor Capability Self-Assessment
- Toolbox Talk Record Template
- Confined Space Entry Permit Template
- Hot Work Permit Template
- Emergency Action Plan Template