Phasing out industrial compressed air systems

Compressed air systems are widely used across Minnesota's industrial sector, yet they are among the least efficient industrial systems, converting less than 10% of electricity input into useful mechanical work. For decades, most of the effort toward compressed air in energy efficiency programs has focused on optimizing these pneumatic components. This study looks at the potential in another approach: phasing out compressed air altogether, wherever we can.

Proposed alternatives to compressed air range from one-to-one replacements with existing, proven technologies to solutions that will require customized engineering or design support. In many cases, compressed air can be replaced with electric or mechanical tools that perform the same work more efficiently and with lower maintenance. Pneumatic hand tools, for instance, likely have electric equivalents, while efficient blowers or vacuums can replace low-pressure cleaning or drying.

However, some systems may require redesigns to replace pneumatic equipment with more efficient mechanical systems. And in cases where pneumatic equipment is required for safety or process reasons, smaller, localized systems can likely replace large, centralized compressors.

Our study will first characterize the stock of compressed air systems across Minnesota's industrial sector, mapping how compressed air is currently used, across which industries, and at what scale. Building on that foundation, we will identify paths for all these approaches and develop guidance and measure definitions that utilities and program administrators can use to incorporate the potential savings from phasing out compressed air into future programs.

This research will help Minnesota lead the nation in advancing the next generation of industrial efficiency by transforming the way industrial compressed-air systems consume energy. With a shift from incremental optimization to a reimagining of industrial applications of compressed air, Minnesota can unlock a new source of long-term, persistent savings in the industrial sector.

This research was made possible by a grant from the Minnesota Department of Commerce, Division of Energy Resources through the Conservation Applied Research and Development (CARD) program, which is funded by Minnesota ratepayers.