R3A05: Carnot Compressor Field Testing
This project will advance an innovative isothermal compression technology to commercial readiness by further development and optimization of air-end components and through field demonstrations.
Carnot Compression Inc.
Recipient
Scotts Valley, CA
Recipient Location
17th
Senate District
28th
Assembly District
$1,573,798
Amount Spent
Active
Project Status
Project Update
In 2025, the company completed lab testing and software modeling with computational fluid dynamics software simulation and settled on a final design iteration. Carnot has modified its design to enable recovery of the heat generated from compression and friction, although this feature was not a part of the field test unit. By using this "waste heat" to reduce heat load serviced by another source, additional energy savings are possible. Carnot has further modified its design to address challenges faced with rotating seals. The design modification may also have a commercial application as a mixed phase pump.
A field test unit was fabricated and installed at a field test location in December 2025. Although the field test unit does not meet its targeted goals for efficiency and air flow production, the project team will evaluate the field test results and assess alternatives for continuing the path toward commercialization.
In 2024, the company completed lab testing and software modeling with computational fluid dynamics software simulation, and tested multiple design iterations. Based on the findings from lab testing, design changes were made and incorporated into a field test beta unit. Preliminary results suggest that the new design has resolved back-pressure issues initially observed, but the unit is still seeing challenges in scaling air flow within the system. The project team continued to work diligently to try to identify ways to increase air flow to the levels necessary for a commercial product.
The Issue
In the United States, industrial air compressors are estimated to consume approximately 12% of manufacturing electricity consumption, or about 400 trillion BTU (Energetics Incorporated. 2012). According to data provided by the Energy Commission, industrial electricity consumption in California was about 41.0 TWh in 2018 (http://www.ecdms.energy.ca.gov/elecbyutil.aspx). Assuming 12% of this energy is dedicated to air compression as it is nationally, then air compression in California requires an estimated 4.9 TWh annually and costs an estimated $640 million for CA ratepayers (assuming an average electricity retail cost of $0.13/kWh). By improving air compressor efficiency by 20%, the energy costs to industrial companies in California could theoretically be reduced by approximately $128 million per year assuming a 100% adoption factor.
Project Innovation
This project will advance an innovative isothermal compression technology to commercial readiness through applied research and development to optimize the air-end components and through field demonstrations to apply the improved components in relevant customer environments.
Project Goals
Project Benefits
The project will effectively demonstrate the technology’s energy efficiency potential at relevant scale to accelerate the path to commercialization, while minimizing the technical, commercial, and engineering risks.
Affordability
This project will save ratepayer costs and energy costs to industrial companies by improving the efficiency of compressors by 20%.
Environmental Sustainability
Improving the efficiency of industrial air compressors results in industry using less electricity and therefore reduces emissions. The technology can also recover heat generated from compression and friction; this waste heat could displace heat generated by fossil fuels, leading to additional environmental benefits.
Key Project Members
Todd Thompson
Hans Shillinger
Chris Finley
Christophe Duchateau
Subrecipients
Oak Ridge National Laboratory
Willdan Energy Solutions, Inc.
Munro & Associates, Inc.
Match Partners
Carnot Compression Inc.
