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Plant Engineering Calculator

Updated Sep 17, 2026

Compressed Air Dryer Pressure Drop Cost Calculator — kW & Annual Cost

Estimate extra compressor power and annual electricity cost associated with dryer pressure drop using airflow and a user-entered specific pressure-power factor.

Live calculationWorking shownPrivate in browser

Inputs

Results

Extra compressor power 1.68 kW
Annual extra energy 10080 kWh
Annual pressure-drop cost $1008
Cost per 0.1 bar $336/year
More actions

Shared links reopen these inputs. Recent and saved calculations stay in this browser unless you clear site data.

Formula

ΔPwr=Q×Δp×factor/100; cost=ΔPwr×hours×tariff.

Your calculation, step by step

These steps use the values currently entered above so the result can be checked independently.

  1. 1.Airflow basis = 8.00 blocks of 100 CFM.
  2. 2.Added power = 8.00 × 0.300 bar × 0.700 = 1.68 kW.
  3. 3.Annual cost = 1.68 × 6000 h × $0.100/kWh = $1008.

How to use this calculator

  1. Enter measured or design values using the units shown beside each field.
  2. Review the live results and the substituted calculation steps before using the estimate.
  3. Check the assumptions below, then continue to a related calculator when the next engineering decision needs another model.

Worked example

800 CFM through a 0.3 bar dryer at 0.7 kW per 100 CFM per bar adds about 1.68 kW before annualization.

Assumptions and limits

  • Pressure-power sensitivity depends on compressor/control system; enter a site or OEM factor.
  • Does not model dryer purge or refrigeration power.

How to interpret the result

Treat the primary result as an engineering screening value, then use the secondary outputs to understand scale, energy or operating impact. Confirm site measurements, equipment limits and applicable standards before making a design or control change.

Questions engineers ask

Why does compressed-air dryer pressure drop increase energy cost?

The compressor must maintain a higher upstream pressure to deliver the required downstream pressure. That additional pressure requirement increases compressor power according to the actual compressor and control response.

What pressure-power factor should I use?

Prefer a measured site value or an OEM performance relationship for the compressor/control system. A generic rule of thumb is less reliable, especially with variable-speed or sequenced compressor plants.

Does this include dryer purge or refrigeration power?

No. This owner isolates the compressor-energy penalty attributable to pressure drop. Add purge loss, heater power or refrigeration power separately when comparing total dryer operating cost.

Continue the calculation

Use the next calculator in the same engineering workflow instead of restarting from search.

compressed air pressure dropcompressed air dryer purge losscompressor specific power
Methodology. MAXScanner shows the governing formula, entered values and calculation outputs so the estimate is auditable. The calculator is a screening aid; assumptions and equipment-specific limits remain part of the engineering review.