Compressed air is one of the most expensive forms of energy in factories, and 20–30% of the air produced in a typical plant is lost to leaks. This tool calculates the flow rate of a leak of a certain diameter, the power wasted in the compressor, and the annual cost .
Formula (critical flow)
κ = 1.4, R = 287 J/(kg· K). The flow rate is given as free air (FAD, 1.013 bar, 20 °C). With C = 1, the results are the same as the U.S. Department of Energy (DOE) leak tables; for true holes with sharp edges, C ≈ 0.61–0.65 can be entered.
Example
In a 7 bar(g) line, a 3 mm leak approximately 11.1 L/s of free air and wastes 4.3 kW of power in the compressor. In 8,000 hours per year, this amounts to 34,600 kWh, or approximately 139,000 ₺ with 4 ₺/kWh of electricity. The annual cost of even a 1 mm leak exceeds 15,000 ₺.
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