Compressor Heat-Recovery ROI Calculator Australia

Author: Byron Raal, CAS Founder-Editor About the author
Checked against: ISO 11011
Date last checked: 18 August 2026

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The compressor heat-recovery ROI calculator quantifies annual fuel saving, carbon abatement, and simple payback for a heat-recovery retrofit on a rotary screw compressor. Inputs include electrical input, operating hours, recovery method (air-cooled, water-cooled, or combined), displaced fuel, and installed cost. Outputs return AUD savings, kg CO2-e abated, payback in months, and 10-year NPV at 7 per cent discount.

Most of a compressor's electricity bill leaves as heat: more than 80 per cent of input energy becomes heat and up to 90 per cent can be recovered as usable heat. — **Figure 1** Most of the bill leaves as heat: more than 80 per cent of a compressor’s input energy becomes heat, and up to 90 per cent can be recovered for hot water or space heating (US DOE Sourcebook pp. 17, 63). Illustrative.

What payback does compressor heat recovery deliver in Australia?

Compressor heat recovery typically pays back in 12 to 36 months on a 45 kW rotary screw running 6,000 hours per year and displacing natural gas at $0.052/kWh, depending on the recovery method (air-cooled hot-air ducting at approximately 80 per cent recovery, water-cooled heat exchanger at approximately 55 per cent, or combined at up to approximately 90 per cent in idealised configurations) and the heat utilisation profile (year-round hot water vs winter-only space heating). 10-year NPV at 7 per cent discount commonly ranges $20,000 to $60,000 against the installed cost.

A rotary screw compressor converts almost all of the electrical energy it draws into heat. The compressed air it delivers carries less than 10 per cent of the input energy; the rest is rejected to ambient via the oil cooler, the aftercooler, the motor, and the cabinet exhaust. In most Australian plants this heat is dumped to atmosphere through a roof vent year-round whenever the compressor runs, while a gas, LPG, or electric resistance boiler downstream consumes mains energy to do the same heating job the compressor is already doing for free, every winter for space heating, year-round for hot water and process pre-heat.

This calculator quantifies the annual saving, the carbon abatement, and the simple payback period for a heat-recovery retrofit on an existing rotary screw compressor. Defaults are anchored to the Australian Government energy.gov.au waste heat recovery guide, the US DOE Improving Compressed Air System Performance sourcebook, and ISO 11011:2013. Fuel prices reflect the ACCC commercial outlook for 2026 supply. Emission factors come from the Australian National Greenhouse Accounts Factors 2025 workbook published by DCCEEW.

In 30 seconds. A 45 kW air-cooled rotary screw compressor retrofitted with hot-air ducting to adjacent space heating typically saves around $6,475 per year on displaced natural gas (at the 2026 ACCC commercial outlook of $0.052/kWh thermal) and clears a simple payback in 22 months on a $12,000 installed cost. This assumes 70 per cent heat utilisation, typical for extended cool-temperate sites (Hobart, Canberra, alpine highlands). Sydney and Melbourne sites with winter-only space-heating demand typically run 50 per cent utilisation, which lifts payback to around 31 months and reduces saving to about $4,625 per year. Override the utilisation profile in the calculator below to match your site. The same compressor on a water-cooled hot-water heat exchanger saves around $4,452 per year with a 67-month payback at higher capital ($25,000 installed). Sites displacing electric resistance heating instead of gas see savings roughly four to five times larger. The displaced electricity costs about five times more per kWh than gas, and gas boilers run at around 85 per cent efficiency while electric resistance is essentially 100 per cent, so the saving ratio per useful kWh of heat delivered is closer to 4.9x.

Scoping a heat-recovery retrofit? Compressed Air Solutions can connect you with qualified Australian compressor specialists who design air-side ducting, water-side heat exchangers, and combined systems sized to your actual flow, climate zone, and downstream heat demand.

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Why Compressor Waste Heat Is the Largest Single Loss in Most Plants

Compression is thermodynamically inefficient. The work done against the gas raises its temperature, and that temperature is then dumped to ambient by the cooling system before the air enters the receiver. Per the US DOE Compressed Air Sourcebook, compressors broadly reject 70 to 90 per cent of input electrical energy as heat across machine classes; for an oil-injected rotary screw at 7 bar gauge discharge pressure with the cabinet exhaust fully ducted to a heat-recovery application, roughly 94 per cent of the electrical input ends up as heat that must be removed. Only the remaining 6 to 10 per cent leaves the package as useful pneumatic energy in the compressed air.

This is not a flaw in any specific compressor design. It is the physical floor for any positive-displacement air compressor operating at industrial pressures. A 45 kW rotary screw running 6,000 hours per year at 70 per cent average load draws 189,000 kWh of electricity from the grid. Approximately 178,000 kWh of that becomes heat. At an indicative Australian electricity price of approximately $0.30/kWh based on typical commercial and industrial tariffs in the 2025-26 financial year (actual rates vary by state, retailer, and contract), the heat fraction alone represents about $53,400 of electricity per year being thrown away through a roof vent. Recovery does not give that electricity back, but it offsets the fuel you would otherwise burn for heating: against cheap natural gas the saving runs to four figures a year, and against electric resistance, LPG, or diesel it climbs into five figures.

The Australian Government waste heat recovery guide states the practical ceiling clearly: as much as 80 per cent of the energy lost as heat in manufacturing processes can be cost-effectively recovered. The same guide notes that average heat-recovery system efficiencies span 50 to 80 per cent in real installations, with peak claims of 95 per cent attainable only in idealised configurations. The calculator below uses the realistic 50 to 80 per cent band as its design space.

Where the Recoverable Heat Actually Lives

Energy flow diagram showing waste heat from a compressor being recovered and converted to usable facility water heating in an Australian industrial system — **Figure 2** Compressor heat-recovery energy flow diagram

The 94 per cent figure for total heat output is a thermodynamic accounting fact. It does not say anything about where in the compressor package the heat is, what temperature it is at, or how easy it is to capture. The recoverable fraction depends entirely on the compressor configuration and the heat-exchange method chosen.

An oil-injected rotary screw with an air-cooled cabinet rejects roughly 70 per cent of its heat through the oil cooler, 15 per cent through the aftercooler, 10 per cent through motor and gearbox losses radiating into the cabinet airspace, and the remaining 5 per cent is carried out in the compressed air leaving the package. If the entire cabinet exhaust is captured by a duct and routed to an adjacent space-heating or process pre-heat application, recovery fractions of 80 to 90 per cent of total electrical input are achievable. The US DOE Improving Compressed Air System Performance sourcebook gives 70 per cent as a conservative floor for this configuration.

The same compressor, when fitted with a water-side heat exchanger on the oil cooler circuit, delivers a much narrower recovery window. Per the DOE sourcebook, water-cooled lubricant-injected rotary screws recover 50 to 60 per cent of input electrical energy when the heat is transferred to a hot water loop. The aftercooler and motor losses remain unrecovered because they are not in the oil circuit. The trade-off is that hot water is a more transportable, more storable, more useful form of heat than warm air, and it can serve year-round process loads that ducted air cannot.

A combined system, where ducted hot air handles space heating in winter and a water-side heat exchanger handles continuous hot water demand, can recover 50 to 80 per cent of input electrical energy in normal field installations, per the Australian Government Department of Climate Change, Energy, the Environment and Water (DCCEEW) waste-heat guidance. Manufacturer peak figures of 85 to 94 per cent reflect idealised conditions (low-temperature heat sink, optimised heat exchanger sizing, near-continuous compressor duty); the 50 to 80 per cent range is the realistic planning baseline for ROI calculations. This is rarely justified at small kW sizes because the controls and dual-mode plumbing add capital that the saving cannot service. Above roughly 75 kW continuous-duty rotary screws, combined systems become competitive on payback.

Heat-Recovery ROI Calculator

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How This Calculator Works

The calculation follows the framework set out in ISO 11011:2013, the international standard for compressed air system energy-efficiency assessment, with cost and emission inputs anchored to Australian sources.

Step 1: Recoverable thermal power. Q_thermal = P_electrical multiplied by the recovery fraction for the chosen method. For a 45 kW compressor at 80 per cent air-side ducting, recoverable thermal power is 36 kW. This is the instantaneous heating capacity available to the recovery system whenever the compressor is loaded.

Step 2: Useful heat per year. E_useful = P_electrical multiplied by operating hours per year multiplied by load factor multiplied by recovery fraction multiplied by utilisation factor. Load factor accounts for the proportion of operating hours that the compressor actually runs at full-load equivalent. Utilisation factor accounts for the proportion of available heat that the downstream load actually consumes; winter-only space heating in temperate Sydney or Melbourne typically clears 50 per cent, year-round hot water generation typically clears 60 per cent, and a continuous process load such as boiler feedwater pre-heating can approach 90 per cent.

Step 3: Annual fuel cost saving. Annual saving (AUD) = (E_useful divided by boiler efficiency) multiplied by displaced fuel price. The boiler efficiency division converts useful thermal energy delivered into the equivalent fuel chemical energy avoided. A non-condensing gas boiler at 85 per cent efficiency consumes 1.18 kWh of gas to deliver 1.0 kWh of heat; the recovery system displaces the gas, not the heat, so the saving scales with the boiler inefficiency.

Step 4: Carbon abatement. kgCO2_saved = (E_useful divided by boiler efficiency) multiplied by 0.0036 GJ/kWh multiplied by the fuel emission factor in kg CO2-e/GJ. Emission factors come from the Australian National Greenhouse Accounts Factors 2025 workbook published by the Department of Climate Change, Energy, the Environment and Water. Natural gas distributed in pipeline is 51.4 kg CO2-e/GJ Scope 1 combined CO2 + CH4 + N2O. LPG is 60.6 kg CO2-e/GJ. Diesel oil is 70.2 kg CO2-e/GJ. Electricity emissions are calculated using the Scope 2 NEM-weighted indicative factor.

Step 5: Simple payback. payback_months = installed_cost divided by ($_saved divided by 12). The calculator pre-fills installed-cost defaults that vary with the recovery method ($12,000 for air-cooled hot-air ducting, $25,000 for water-cooled plate heat exchanger systems, $55,000 for combined air plus water systems). These defaults are first-pass mid-band figures intended for capex screening; actual installed cost varies materially with site access, ductwork distance, existing plumbing, and the specific compressor OEM service network. Override the installed-cost field with a site-specific quotation as soon as one is available.

Step 6: 10-year net present value at 7 per cent discount. Standard NPV calculation. NPV equals the negative installed cost plus the sum of annual cost savings discounted by (1.07)^t for years 1 through 10. The 7 per cent rate is a typical Australian commercial hurdle for energy-efficiency capital. NPV becomes negative when the payback exceeds the discounted lifetime of the equipment, which is the right signal to walk away from the project even if the simple payback looks acceptable.

The NPV calculation holds the annual saving constant in nominal dollars across the 10-year horizon. Australian gas and electricity prices have escalated 4 to 8 per cent per year through 2022 to 2025; if your forecast incorporates fuel-price escalation, NPV is understated by roughly 10 to 25 per cent at the 7 per cent discount rate. Override the discount rate to a real-terms hurdle (around 4 per cent after long-run CPI) if you want a real-terms NPV that matches a constant-saving model.

Two Worked Examples Side by Side

Same 45 kW rotary screw, same 6,000 operating hours per year, same 70 per cent load factor, same displaced natural gas at $0.052/kWh ($14.43/GJ commercial outlook for 2026 supply per the ACCC), same 85 per cent boiler efficiency. The only differences are the recovery method, the recovery fraction it delivers, the heat utilisation factor that the downstream load can absorb, and the installed cost.

Variable	A. Air-cooled, hot-air ducted	B. Water-cooled, hot water HX
Compressor input power	45 kW	45 kW
Operating hours per year	6,000	6,000
Load factor	70%	70%
Recovery fraction	80%	55%
Utilisation factor	70% (extended cool-temperate space heating)	70% (extended cool-temperate site, e.g. Hobart, Canberra)
Useful heat delivered	105,840 kWh/yr	72,765 kWh/yr
Annual gas saving	$6,475 /yr	$4,452 /yr
Annual carbon abatement	23,041 kg CO2-e/yr	15,841 kg CO2-e/yr
Installed cost	$12,000	$25,000
Simple payback	22 months (1.9 yr)	67 months (5.6 yr)
10-year NPV at 7%	$33,477	$6,266

The two configurations land at very different payback profiles despite running on the same compressor. The air-cooled ducted system clears most plant-level capital approval thresholds without further analysis. The water-cooled exchanger system is marginal at the same compressor size and would typically require a larger compressor (75 kW or above), a higher utilisation factor (process load above 80 per cent), or a more expensive displaced fuel (LPG or electric resistance) before the NPV becomes compelling.

Australian Energy Prices and Why the Numbers Move

The displaced fuel choice drives the saving more than any other input. Natural gas at the ACCC commercial outlook of $14.43/GJ for 2026 supply works out to $0.052/kWh thermal. LPG, paid bulk on a delivered basis, lands around $0.080/kWh thermal. Electric resistance heating runs at the full $0.30/kWh commercial and industrial tariff. Diesel or distillate heating oil at commercial bulk prices is around $0.150/kWh of fuel thermal energy at typical Australian delivered prices for 2026 supply (approximately $1.60 per litre divided by ~10.7 kWh/L heating value). The calculator divides this by your boiler efficiency to arrive at the cost per useful kWh delivered.

A site running an electric resistance boiler stands to gain roughly four to five times the saving of a site running a natural gas boiler at the same load profile, because the displaced fuel is about five times more expensive per kWh of fuel input. The actual saving ratio is closer to 4.9x once gas boiler efficiency (around 85 per cent) and electric resistance efficiency (effectively 100 per cent) are both accounted for. This is the single biggest reason heat recovery economics vary so wildly across plants, and the reason that the same retrofit specification can be a no-brainer at one site and unfundable at another. Always check the displaced fuel price input against your own tariff or supply contract before quoting the saving figure to a finance team.

State-by-state variation matters less than fuel-type variation, but it is not negligible. Western Australia and the Northern Territory sit outside the east-coast gas market the ACCC reports on, so a single “east coast” benchmark does not transfer directly. WA industrial gas is generally at or below east-coast levels thanks to the state’s domestic gas reservation policy; NT pricing is more variable because of limited supply options. Commercial LPG delivered to remote sites carries a freight premium that can exceed $0.02/kWh on top of the bulk price. The calculator’s defaults reflect east-coast urban industrial tariffs; override the price field for any site where the local fuel cost differs materially.

Need a Heat-Recovery Retrofit Scoped to Your Site?

The calculator gives you the order of magnitude. A scoping engineer gives you a specification that procurement can act on. Compressed Air Solutions can connect you with Australian specialists who size air-side and water-side recovery systems to your actual flow, downstream heat demand, and fuel-type displacement.

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Where Heat Recovery Pays Back Fastest

Figure 3 The four heat-recovery configurations that clear a 3-year simple payback in most Australian retrofits.

Heat recovery is not universally economic. The four configurations below cover the great majority of Australian retrofit scenarios that clear a 3-year simple payback at default fuel prices.

Air-cooled ducted into adjacent factory or warehouse heating. The fastest payback. A 30 to 75 kW rotary screw running 5,000 to 8,000 hours per year, dumping 25 to 60 kW of heat into a roof vent, can be re-ducted into an adjacent bay needing space heating in winter or pre-heating make-up air in cool-temperate or alpine climates. Installed costs are modest, controls are simple, and utilisation factors above 60 per cent are common in workshops, warehouses, and light manufacturing during the May-to-September period.

Water-cooled exchanger into continuous process hot water. The most reliable payback at large sites. Food processing, dairy, beverage, abattoir, and tannery operations run continuous hot water loads at 50 to 80 °C that match the temperature window a compressor oil cooler can deliver. Above 75 kW compressor size, with a utilisation factor above 80 per cent, water-side recovery typically clears a 3-year payback even at conservative gas prices.

Boiler feedwater pre-heating. A specific case of water-side recovery that deserves separate treatment. The standard engineering rule for steam and hot water boilers is approximately 1 per cent boiler fuel saving for every 5 to 6 °C rise in feedwater temperature. Pre-heating boiler feedwater from 15 °C to 50 °C therefore typically saves 6 to 8 per cent of boiler fuel on top of the heat-recovery saving. Plants running a steam boiler or a high-temperature hot water boiler should always model boiler feedwater pre-heat as the first option for compressor heat utilisation. The energy audit guide covers the boiler-feedwater integration in more detail.

Wash bay or parts washer pre-heat. Industrial wash bays in automotive workshops, equipment rebuild facilities, and food-contact cleaning operations typically run hot water at 50 to 65 °C with intermittent draw patterns. A buffer tank between the compressor heat exchanger and the wash bay smooths out the demand mismatch and lets the recovered heat displace electric or gas water heating. Smaller scale than process loads but often a clean economic case at 30 to 75 kW compressor sizes.

What Heat Recovery Doesn’t Do

Heat recovery is widely sold and frequently mis-sold. Six common misconceptions to clear before specifying a system.

It does not reduce compressor electrical demand. The compressor draws the same kW from the grid whether the heat is captured or vented. The saving comes from displacing a separate fuel that would otherwise heat the same load.

It does not save energy in summer if the only demand is winter space heating. Utilisation factor multiplies linearly through the saving calculation. A 50 per cent utilisation factor on six months of useful demand cuts the saving in half compared with a year-round application. The calculator’s utilisation profiles separate the year-round, extended-season, and winter-only cases.

It does not always pay back at small kW sizes. Below about 22 kW compressor size, the installed cost of even a basic ducted system is hard to recover within a 5-year horizon unless the load profile is very high (24/7 operation) or the displaced fuel is electric resistance.

It does not eliminate the need for a backup heating source. The compressor only delivers heat when it is running. Plants that need heat outside compressor operating hours, or during compressor maintenance shutdowns, must retain a primary heat source that can carry the full load. Heat recovery is a fuel-saver, not a heat-source replacement.

It does not improve compressed air quality. Heat recovery touches the cooling circuit, not the compressed air path. Issues with pressure dew point, oil carry-over, or particulate count are independent and need to be addressed through dryer specification and filtration.

It does not work without controls. A heat-recovery system without modulating controls dumps high-grade heat into a load that does not need it, or starves a load that does. Diverter dampers on air-side systems, three-way mixing valves on water-side systems, and a temperature-sensing controller that watches both the supply and the demand side are part of every credible installation. Cutting the controls to save capital almost always destroys the payback.

How to Use This Calculator

Set the compressor power and operating hours from your plant data. Set load factor honestly: if a metering survey is not available, 60 to 70 per cent is a defensible default for a single-shift workshop, 80 per cent for two-shift production, and 50 per cent for a process plant with significant idle periods. Choose the recovery method that fits your physical site (an air-cooled compressor cabinet that vents to a roof vent points to ducted hot air; a water-cooled compressor with an existing chilled-water or process-water tie-in points to a plate heat exchanger). Pick the utilisation profile that matches the downstream load.

The recovery fraction defaults are taken from the US DOE sourcebook and the Australian Government waste heat recovery guide. Override them only if you have manufacturer-specific data for the particular compressor model. Be sceptical of OEM marketing claims of 95 per cent or higher recovery; these are achievable in laboratory conditions but rarely sustained in the field across a year of varying load.

Override the fuel price field with your actual contracted gas or LPG tariff if it differs materially from the calculator default. Override the boiler efficiency field if your existing boiler is condensing (90 to 95 per cent) or significantly under-maintained (70 to 78 per cent). The installed cost field should be replaced with a specific quotation as soon as one is available; the default ranges are useful for first-pass screening but vary widely with site access, ductwork distance, and existing plumbing.

For a deeper assessment that integrates heat recovery with leak reduction, pressure optimisation, and full system efficiency, see the compressed air energy audit guide. For sizing the underlying compressor before retrofit, see the system design guide.

Frequently asked questions

How much heat does a rotary screw compressor produce?

Approximately 94 per cent of the electrical energy a rotary screw compressor draws from the grid is rejected as heat. For a 45 kW compressor running at full load, this is around 42 kW of heat output that must be removed by the oil cooler, the aftercooler, and ambient cabinet losses. Only the remaining 6 per cent or so, the conservative floor of the 6 to 10 per cent range quoted above, leaves the package as useful pneumatic energy in the compressed air. This is a thermodynamic floor for any positive-displacement air compressor at industrial pressures, not a defect in any specific design.

What recovery efficiency is realistic for a heat-recovery retrofit on an oil-cooled rotary screw?

Per the US DOE Improving Compressed Air System Performance sourcebook, water-cooled lubricant-injected rotary screws transferring heat to a hot water loop typically recover 50 to 60 per cent of input electrical energy. Air-cooled rotary screws with the cabinet exhaust fully ducted to a heating application recover at least 70 per cent and typically 80 per cent in well-controlled installations. Combined systems that capture both air-side and water-side losses can reach 85 to 94 per cent in idealised configurations. The Australian Government waste heat recovery guide gives 50 to 80 per cent as the realistic average across heat-recovery systems.

What payback period is realistic for a compressor heat recovery retrofit in Australia?

Air-cooled ducted hot-air systems on 30 to 75 kW rotary screws displacing natural gas typically clear a 18-to-30-month simple payback when the utilisation factor is 60 per cent or higher. Water-cooled hot water heat exchanger systems on the same size compressor typically clear a 4-to-7-year payback. Where the displaced fuel is electric resistance heating instead of gas, payback periods fall by roughly a factor of four to five because the fuel cost displaced is roughly five times higher per kWh of fuel input, and the saving per useful kWh delivered scales by about 4.9x once boiler efficiencies are accounted for. Below 22 kW compressor size, payback is rarely under 5 years.

Does heat recovery work with VSD compressors?

Yes, with one caveat. A variable speed drive compressor matches output to demand by reducing motor speed, which proportionally reduces both compressed air output and waste heat output. The thermal output therefore tracks the compressed air load. This is helpful for sites where the heating demand also tracks the compressed air load, but it can be a problem where the heating demand is steady and the compressed air demand is variable. A small buffer tank on the water side, or a backup heat source on the air side, smooths the mismatch.

What is the best application for compressor waste heat?

In order of typical payback speed: air-side ducting into adjacent factory bay or warehouse space heating, water-side heat exchange into continuous process hot water, boiler feedwater pre-heating, and wash-bay or parts-washer pre-heat. The first three are economic at 30 kW compressor sizes and above when the utilisation factor exceeds 60 per cent. Wash-bay applications need a buffer tank to bridge the demand-supply mismatch but are otherwise straightforward. The single best predictor of payback speed is the utilisation factor of the downstream load, not the compressor size or the recovery method.

Are there Australian standards or grants supporting compressor heat recovery?

ISO 11011:2013 Compressed air, Energy efficiency, Assessment is the methodology framework cited internationally and by Australian energy auditors. The Australian Government energy.gov.au waste heat recovery guide is the primary domestic authority. Federal grant routes for compressed-air efficiency upgrades and heat-recovery projects change frequently, and most are not open to a typical industrial heat-recovery retrofit (for example the Community Energy Upgrades Fund is restricted to local-government bodies, and the Powering the Regions Fund targets emissions-intensive trade-exposed industries). Check business.gov.au and your state energy department for currently open, industrially eligible programs. State-scheme support is administered separately: the Victorian Energy Upgrades scheme (Victoria) and the Energy Savings Scheme (NSW) are the two largest active certificate schemes for energy-efficiency activities. Queensland does not currently operate an equivalent statewide certificate scheme. Operators should verify current eligibility through business.gov.au and through their state energy department; the Clean Energy Regulator administers separate carbon-credit and renewable-energy schemes that may or may not apply to a heat-recovery project. Eligibility is typically tied to a measurement and verification plan against ISO 11011 or an equivalent assessment framework.

Get Matched with a Compressed Air Heat-Recovery Specialist

Describe your compressor, operating profile, location and the heat demand you want to serve. We can review your brief and discuss a suitable Australian provider if one is available. We ask for your written permission before an introduction and explain any referral payment arrangement. There is no cost to enquire.

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Calculator disclaimer. This calculator provides indicative estimates only, based on the inputs you supply and the standard assumptions stated on this page. Results are not a substitute for a site-specific assessment by a qualified engineer. Actual energy use, savings, equipment sizing, and payback depend on factors this tool cannot capture, including your duty cycle, ambient conditions, existing plant, and electricity tariff. Do not make purchasing or capital decisions on these figures alone. Compressed Air Solutions accepts no liability for decisions made on the basis of this tool.

1What payback does compressor heat recovery deliver in Australia?

2Why Compressor Waste Heat Is the Largest Single Loss in Most Plants

3Where the Recoverable Heat Actually Lives

4Heat-Recovery ROI Calculator

5How This Calculator Works

6Two Worked Examples Side by Side

7Australian Energy Prices and Why the Numbers Move