Gas loss cost calculator
Estimate the cost of gas loss
Enter your average monthly usage, choose a gas price, and explore different loss assumptions.
Annual leak-cost scenario
Enter your monthly usage to see the cost scenarios.
- Monthly gas value lost
- Monthly quantity lost
- Annual quantity lost
Illustrative cost scenario based on your inputs and selected loss percentage—not a measurement of your facility’s leakage or a guarantee of savings.
Calculation notes and limitations
Example prices and loss percentages are illustrative, not verified rates for your facility. Annual figures assume the entered monthly average continues for 12 months. Not all gas consumption outside the finished product is leakage.
Actual leakage may be zero, lower, or higher. Recoverable savings depend on confirmed losses, repairs, operating conditions, and purchasing terms. This calculator does not determine worker exposure or compliance status.
CO₂ comparison: Assumes a 12-oz can (12 U.S. fluid ounces), 3.5 carbonation volumes, and 1.96 grams CO₂ per liter per volume. Based on UF/IFAS Extension, FS379. Carbonation levels vary by beverage.
Natural-gas comparison: Uses 56.6 MMBtu of annual site natural-gas consumption per U.S. household using natural gas, from the EIA 2020 Residential Energy Consumption Survey.
The annual percentage applies to installed ammonia charge. In the 2021 UW–Madison/IIAR study by Claas and colleagues, six systems at five plants were studied. Two minimally modified systems had about 4.8% and 6.6% annual total refrigerant loss; system changes confounded larger estimates. Small measured component leaks were not the principal explanation of total loss. These presets are scenarios informed by limited data, not promised OGI recovery.
The comparison uses 150 lb of ammonia per cylinder fill, a documented Hill Brothers supply configuration, not gross cylinder weight or the only cylinder size. Monthly results are annual loss divided by 12; fills are comparisons, not delivery or refill schedules.
The annual percentage applies to installed SF₆ mass. For mixtures, enter SF₆ mass, not total mixture mass. Widger and Haddad’s 2018 Great Britain network study reported historical annual rates around 0.46% for distribution and 1.29% for transmission over its study periods. These network-level observations include handling and maintenance losses; they are not every breaker’s rate or universal present-day values.
The comparison uses a 9-kg conventional-breaker charge from Siemens, not a universal equipment charge. Example replacement prices are illustrative, not supplier quotations. Monthly results average annual loss over 12 months; equivalent charges do not forecast refill work.
Loss presets are illustrative equipment-leakage scenarios, not EPA rates, permitted limits or conversion efficiency. EPA AP-42 §8.10 distinguishes exit-stack emissions from equipment leaks and notes limited data for the latter. This calculation concerns SO₂ lost before acid conversion.
The stoichiometric comparison uses molecular weights of 64.064 for SO₂ and 98.078 for sulfuric acid from NIST. It is not a plant-conversion or repair-recovery forecast. The acid-strength and valuation basis are stated below; acid value is gross reference value, not net profit, avoided operating cost or guaranteed savings.
Unit conversions retain the unrounded physical quantity and rate. Nonterminating conversions display up to 15 significant digits, rounded toward zero. Comparisons use full unrounded values; displayed monthly averages do not define actual loss timing.
Optical Gas Imaging
Locate the sources of gas loss
Optical gas imaging scans equipment and process areas for emissions detectable by the selected camera. A documented leak list helps maintenance focus inspection and repair, which can reduce avoidable material loss and operating cost.
Technical limitation: Visibility depends on the gas, camera, background, viewing geometry, weather, and operating conditions. OGI does not by itself measure concentration, worker exposure, or leak rate.
Azurite Leak Inventory
Follow leaks through repair and verification
Keep identified leaks organized so planners and maintenance teams can prepare repairs and coordinate follow-up.
- Mapped locations and consistent leak IDsConnect each finding to the facility drawing and a common reference for work orders.
- Supporting photos and videoKeep detection media and repair documentation with the leak record.
- Repair status and verificationSee which leaks remain open, which repairs need verification and which have been verified.
Certified Industrial Hygienist oversight · Nationwide project support
Request a leak survey