How compressed air inefficiencies undermine net zero goals

The opinions expressed in this article are those of the guest post contributor, and not of Gas Outlook.

As the oil and gas sector ramps up efforts to meet net zero targets, operational emissions have become a central focus. Electrification, carbon capture, and methane leak detection often dominate the conversation. However, one frequently-overlooked source of carbon emissions lies within the compressed air systems that power many industrial processes.

Compressed air is widely considered the “fourth utility,” essential to operations yet commonly under-monitored in terms of energy performance. Inefficiencies in these systems not only drive up operational costs but also result in significant, avoidable emissions.

Compressed air systems are notoriously energy intensive. According to the U.S. Department of Energy, electricity costs represent approximately 75% of a compressed air system’s total lifecycle cost. Of that, studies indicate that 20% to 30% of the energy is typically wasted due to system inefficiencies such as leaks, over-pressurisation, poor system design, inadequate system controls, and improperly-sized equipment.

In real-world terms, a quarter-inch air leak at 100 pounds per square inch (psi) can waste more than $2,500 in electricity annually. When multiplied across an industrial site with dozens of compressors and extensive distribution piping, the cumulative losses become substantial — not only in economic terms but also in associated emissions. For facilities powered by fossil fuel-based electricity, this waste directly contradicts decarbonisation goals.

Undermining net zero

Inefficient compressed air systems create a two-fold challenge. First, they increase scope 2 emissions, since more electricity is required to meet the same operational output. Second, they add complexity to energy forecasting and load management. Compressors that operate continuously, regardless of demand, exacerbate base load requirements. This heightened demand can hinder efforts to align operations with renewable energy integration, particularly during peak periods when fossil back-up systems may be required.

In some cases, overbuilt systems, often installed as a buffer for future demand or to avoid downtime, contribute to constant low-efficiency operation. Compressors running at partial load consume disproportionate amounts of energy per unit of compressed air delivered, again raising indirect emissions.

The carbon footprint of these inefficiencies, while diffuse, is significant when assessed across a portfolio of assets or supply chain partners.

Several operational factors continue to drive energy losses in compressed air systems. These inefficiencies often fly under the radar because compressed air is viewed as a background utility rather than a strategic energy asset. As a result, optimisation efforts frequently prioritise more visible sources of emissions, leaving significant savings on the table.

Several common issues contribute to compressed air waste including:

— Lack of performance monitoring: Without visibility into system metrics, inefficiencies often persist undetected.

— Reactive maintenance: Many facilities rely on maintenance only after performance declines or failures occur.

— Outdated control systems: Older systems may not adapt well to variable demand or communicate effectively with broader energy management platforms.

— Design oversights: Systems are frequently oversized or configured without optimisation for energy efficiency.

Addressing these factors provides not only emissions reductions but also operational benefits, including lower energy costs and improved system reliability.

Optimising compressed air systems presents a clear opportunity to align operational performance with sustainability goals. Routine leak detection and repair can yield double-digit energy savings. Demand-side optimisation, ensuring compressed air supply aligns with actual use, can reduce unnecessary run time and idle losses. Regular audits offer a data-driven foundation for capital planning and lifecycle management.

Facilities can also improve performance through updated control technologies that enable real-time system management and integration with plant-wide energy strategies. These upgrades often deliver short payback periods, particularly in regions with high electricity costs or emissions intensity.

Relevant technologies, including industrial air compressor system products with integrated controls, are evolving to support these strategies, offering scalable ways to monitor and improve performance.

Implications for ESG and reporting

As environmental, social, and governance (ESG) frameworks evolve, the carbon intensity of all utilities, including compressed air, is receiving greater scrutiny. Including compressed air system efficiency in emissions reporting provides a more accurate operational profile and demonstrates attention to often-neglected sources of carbon.

Companies with robust monitoring and optimisation strategies may benefit from stronger ESG positioning, particularly as new reporting directives such as the EU’s CSRD require greater transparency in scope 1 and 2 emissions.

Compressed air systems play a foundational role in industrial operations but often operate inefficiently. The resulting energy waste contributes directly to a facility’s carbon footprint, undermining progress toward net zero targets. Addressing these inefficiencies with data-driven strategies offers a pathway to measurable emissions reductions and operational savings. As global decarbonisation efforts intensify, compressed air optimisation deserves a more prominent role in energy and sustainability planning.

Jeffry Kahn is the President of CAM Technologies, Inc., a global leader in compressed air system management. With over 20 years of experience in engineering, controls, and automation, Kahn has spent the past 12 years driving innovation and efficiency at CAM. He is passionate about developing solutions that support a more sustainable future and creating success stories for customers across industries. 

(Writing by Jeffry Kahn; editing by Sophie Davies)