Kotech KDS-20/20 Compressor Powers Down-the-Hole Drilling for Turkish Mining & Construction Projects

The Kotech KDS-20/20 diesel skid-mounted rotary screw compressor was deployed for a 180-day drilling campaign across Turkish quarries and construction sites in the Karaman and Central Anatolia regions. Delivering 20 m³/min at 20 bar (290 PSI), the unit powered DTH hammers through hard limestone, marble, and granite formations. Powered by a 242 kW diesel engine with capacity control for fuel efficiency, the compressor achieved 98.5% uptime and reduced fuel consumption by 15–20% compared to older fixed-speed units. The compact skid-mounted design allowed easy repositioning with standard 4×4 vehicles across rough terrain. The case study demonstrates the KDS-20/20's capability for reliable, high-pressure drilling in demanding quarry and construction environments.

Mining, Quarrying, Construction & Infrastructure Karaman & Central Anatolia Regions, Turkey 2025–2026

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Client / Project

Turkish Open-Pit Mining & Infrastructure Drilling Project

Industry

Mining, Quarrying, Construction & Infrastructure

Project Location

Karaman & Central Anatolia Regions, Turkey

Implementation Year

2025–2026

Project Duration

90 Days

Customer Pain Points

Drilling contractors in Turkey's central Anatolia region face a set of challenges that test both equipment and crews. The area's hard limestone, marble, and granite formations are abrasive and demanding, requiring consistent high-pressure air to keep DTH hammers firing at full power . The client, a Turkish drilling contractor operating across multiple quarry and construction sites, had been struggling with their legacy compressor fleet for years.

Inconsistent pressure was the biggest complaint. The contractor's older units would start the day strong, but as the heat built up and the compressor worked harder, pressure would sag. At depths beyond 30–40 metres, the DTH hammers would lose impact energy, penetration rates would drop, and the drill string would start to bind. The site foreman put it bluntly: "When the compressor gets tired, we get tired. And we're paid by the metre, not by the hour."

Fuel consumption was the second headache. The contractor's fleet ran on diesel, and fuel prices in Turkey have been volatile. Their older compressors were fuel-hungry, burning through a full tank in less than a shift and forcing refueling trucks to make multiple trips to the site. The project manager had calculated that fuel was eating up nearly 30% of their operating budget—a number he was determined to cut.

Mobility was the third issue. The contractor moved equipment frequently between sites—sometimes weekly—and the old compressors were heavy, difficult to tow, and slow to reposition. One operator complained that moving a compressor from one quarry face to another took longer than the drilling itself.

Solutions

Kotech deployed the KDS-20/20 diesel skid-mounted rotary screw air compressor—a unit designed specifically for demanding drilling applications in tough environments . The KDS-20/20 delivers **20 m³/min (706 CFM) at 20 bar (290 PSI) , providing the volume and pressure needed to drive DTH hammers through hard rock formations.

The unit is powered by a heavy-duty diesel engine rated at 242 kW, with enough fuel capacity to run an entire shift without refueling. This was a critical feature for the Turkish contractor, who had been losing time to midday refueling stops with their older equipment. The KDS-20/20's fuel efficiency is further enhanced by Kotech's capacity control system, which automatically adjusts engine speed to match actual air demand—reducing fuel waste during rod changes and idle periods.

The skid-mounted design was another key advantage. The KDS-20/20 is compact and lightweight relative to its output, making it easy to manoeuvre and transport between sites. The client could reposition the unit with a standard 4×4 vehicle, eliminating the need for heavy tow trucks. The chassis is built to handle rough terrain, with high ground clearance and robust construction that withstands the punishment of quarry floors. Kotech has designed the KDS series to operate reliably in ambient temperatures from -20°C to +50°C, making it suitable for Turkey's hot summers and cold winters alike .

Dust protection was also addressed. The KDS-20/20 features a heavy-duty air intake filtration system designed for dusty environments, protecting the rotary screw airend from abrasive wear. The filter system includes a pre-cleaner that removes airborne particles before they reach the main filter element.

Implementation Steps

Site assessment and technical review. Kotech engineers evaluated the client's drilling requirements, including hole diameter, target depth, and typical formation types. They also reviewed the client's existing air distribution system to ensure compatibility with the KDS-20/20's pressure and flow characteristics.
- Equipment configuration. The KDS-20/20 was configured for Turkish operating conditions, with the tropical cooling package and heavy-duty filtration system installed prior to delivery.
- Logistics and delivery. The unit was transported to the client's primary quarry site in the Karaman region, with the skid-mounted design allowing for straightforward unloading using a standard forklift or crane.
- On-site integration and coupling. The compressor was connected to the client's DTH drilling rigs using existing air hoses and fittings. The integration process was quick, requiring no modifications to the client's existing equipment.
- Commissioning under real conditions. The KDS-20/20 was run through a full drilling cycle at the quarry, with Kotech technicians monitoring pressure stability, airflow, and engine performance. The client's drilling crews observed the commissioning and were trained on daily operation and maintenance.
- Operator training. Hands-on training sessions covered startup and shutdown procedures, pressure adjustment, fuel management, and routine maintenance checks.

Customer results

This case study follows the Kotech KDS-20/20 through a 180-day deployment across multiple drilling sites in Turkey's central Anatolia region.

The first site was a marble quarry in the Karaman area. The client was drilling 90–115 mm blast holes to depths of 30–50 metres in hard limestone and marble formations. The KDS-20/20 was positioned at the quarry face and connected to the client's DTH drilling rig. From the first run, the difference was noticeable. The stable 20 bar pressure kept the hammer firing at full impact energy through the entire hole depth, something the client's old compressors couldn't sustain beyond 30 metres. The site foreman commented after the first week: "The pressure doesn't sag. We're not losing impact energy halfway down the hole. That means faster drilling and fewer stuck rods."

Fuel efficiency was proven immediately. The KDS-20/20's capacity control system reduced engine speed during rod changes and idle periods, cutting fuel consumption compared to the fixed-speed units the client had been using. The project manager estimated that the unit used approximately 15–20% less fuel per shift than the older compressors. Over the 180-day campaign, that translated into meaningful cost savings—enough to make a visible difference in the project budget.

The dust challenge came during a week of dry, windy weather. The quarry was producing heavy limestone dust that had clogged the client's previous compressors and forced daily filter changes. The KDS-20/20's pre-cleaner handled the load without complaint. The main filter showed only moderate loading at the end of the week, and the unit continued running without interruption. The maintenance supervisor noted: "Our old units would have needed filter changes every two days in that dust. This one went all week."

Mobility was tested when the client needed to move the compressor from one quarry face to another—a distance of about 500 metres across rough ground. The skid-mounted design and lightweight construction allowed the crew to reposition the unit using a standard 4×4 truck, a task that had previously required a heavy tow vehicle. The move took less than an hour, compared to the half-day it had taken with the old equipment.

The second site was a construction project outside Ankara, where the client was drilling foundation holes for a new infrastructure development. The KDS-20/20 was deployed alongside a separate rotary drilling rig, providing compressed air for both DTH drilling and pneumatic tools. The unit ran continuously for 30 days, with no unscheduled downtime. At the end of the project, the client's drilling supervisor summed it up: "I've been doing this for 20 years. I've seen a lot of compressors come and go. This one just works."

Total uptime across the 180-day campaign: 98.5%.

## Products Used in This Case

- Kotech KDS-20/20 Diesel Skid-Mounted Air Compressor– 20 m³/min at 20 bar, 242 kW diesel engine, compact skid chassis, heavy-duty filtration system, capacity control for fuel efficiency. Application: DTH drilling, quarrying, construction.

Products Used in This Case

KOTECH KOE+ Series | High-Efficiency PM VFD Rotary Screw Air Compressor

FAQ (Frequently Asked Questions)

What makes the KDS-20/20 suitable for DTH drilling in hard rock?

The KDS-20/20 delivers 20 m³/min at 20 bar (290 PSI), providing the volume and pressure needed to drive DTH hammers through hard limestone, granite, and marble formations. The stable pressure output ensures consistent hammer impact energy through the full hole depth, reducing wear on the drill string and improving penetration rates. In the Turkish quarry project, the unit maintained steady pressure to depths beyond 40 metres—something the client's previous compressors could not achieve.

How does the KDS-20/20 reduce fuel consumption compared to older compressors?

The KDS-20/20 features Kotech's capacity control system, which automatically adjusts engine speed to match real-time air demand. When the drill stops for rod changes or idles between holes, the engine RPM drops, reducing fuel consumption without affecting performance when the drill is running. The unit's efficient rotary screw airend also contributes to fuel savings. In the Turkish project, the client reported a 15–20% reduction in fuel consumption per shift compared to their older fixed-speed compressors.

Is the KDS-20/20 easy to move between drilling sites?

Yes. The KDS-20/20 is built on a compact skid-mounted chassis that is both lightweight and robust. It measures 3,900 mm × 2,100 mm × 1,750 mm and weighs approximately 650 kg, allowing it to be repositioned with a standard 4×4 vehicle or forklift. The client in the Turkish project moved the unit between quarry faces and between separate sites with minimal effort, saving time and reducing the need for heavy transport equipment.

How does the compressor handle dusty quarry environments?

The KDS-20/20 is equipped with a heavy-duty multi-stage air intake filtration system that includes a centrifugal pre-cleaner to remove airborne particles before they reach the main filter element. This two-stage approach extends filter life and protects the rotary screw airend from abrasive wear. In the Turkish quarry project, the unit operated through a week of heavy dust with only moderate filter loading, while the client's previous compressors had required daily filter changes under the same conditions.

What kind of holes can the KDS-20/20 drill?

The KDS-20/20 is suitable for DTH drilling applications with hole diameters ranging from 60 mm to 150 mm, depending on the hammer and formation. In the Turkish project, the unit was used for 90–115 mm blast holes in marble and limestone, at depths of 30–50 metres. For larger holes or deeper drilling, a higher-capacity compressor may be required.