Why include unloaded energy?

Many compressors draw material power while producing little useful air off-load, so ignoring unloaded energy understates the real interval cost.

Is the demand charge always added?

No. Add only the portion attributable or allocated under the site tariff and the approved costing method for this work.

Can horsepower replace measured kW?

Not for a decision-grade cost. Actual electrical input and control behavior determine energy consumption, so use measured data when available.

What output should enter job cost?

Use the total allocated compressor cost for the same production interval, then avoid adding its components a second time.

Abrasive Blasting, Shot Peening & Surface Prep calculator

Abrasive Blast Compressor Energy and Demand Cost Calculator

Price an interval of blast compressor energy from loaded power and hours, metered unloaded energy, the energy rate and the demand charge assigned to the work. Accepted area turns the total into a unit cost.

What this calculator does

Loaded and unloaded compressor energy priced at the tariff rate, plus the demand charge allocated to the interval.

Formula used

Loaded energy (kWh) = loaded power (kW) × loaded hours
Total energy = loaded energy + metered unloaded energy
Energy charge = total energy × energy rate
Total cost = energy charge + allocated demand charge

Inputs explained

Loaded Compressor Power: Measured average input power while supplying blast demand.
Loaded Hours: Hours at loaded blast power during the cost interval.
Unloaded Energy: Metered energy used while running without blast output.
Energy Rate: Applicable marginal or blended energy rate.
Allocated Demand Charge: Demand charge assigned to this blast interval.
Accepted Blast Area: Accepted area produced during the same interval.

How to use the result

Best suited to energy cost allocation, shutdown control business case, quote utility input.
Does not model compressor control dynamics or part-load curves. Taxes, riders and time-of-use tiers need tariff-specific extension. Allocation is not the same as measured incremental demand.

Current U.S. benchmarks

As of Jul 2026, industrial electricity averages 9.8 cents per kWh across the U.S. (EIA), up 4.7% from a year earlier. State averages range widely, so plants should confirm against their own tariff.

Common questions

Why include unloaded energy? Many compressors draw material power while producing little useful air off-load, so ignoring unloaded energy understates the real interval cost.
Is the demand charge always added? No. Add only the portion attributable or allocated under the site tariff and the approved costing method for this work.
Can horsepower replace measured kW? Not for a decision-grade cost. Actual electrical input and control behavior determine energy consumption, so use measured data when available.
What output should enter job cost? Use the total allocated compressor cost for the same production interval, then avoid adding its components a second time.

Last reviewed 2026-10-01.