Kotech KOE-110(VSD) Frequency-Controlled Compressor Optimizes Energy Use in Turkey’s Power Generation Industry

Turkey's power generation sector relies heavily on domestic lignite coal, with plants like the Yeniköy and Kemerköy facilities in the Gökova Bay region generating approximately 5% of the country's electricity . But keeping a thermal power plant running 24/7 isn't just about burning coal—it's about keeping every auxiliary system operational, and compressed air is one of the most critical.

A large thermal power plant in Turkey's Muğla province was running a fleet of fixed-speed air compressors to supply instrument air and service air across the facility. The plant's operations team had been dealing with three persistent problems that were eating into their budget and reliability.

Energy waste was the first issue. The fixed-speed compressors ran at full capacity regardless of demand. At night, when instrument air consumption dropped, the compressors would still run at 100% and then unload—a cycle that wasted a significant amount of electricity . The plant's energy manager had tracked the numbers and knew that compressed air accounted for roughly 12–15% of the facility's auxiliary power consumption. With Turkey's industrial electricity prices climbing, every wasted kilowatt-hour meant real money.

Pressure fluctuations were the second headache. The plant's compressed air system fed pneumatic actuators, control valves, and soot-blowing systems across the boiler house and turbine hall. When the fixed-speed compressors cycled on and off, pressure would spike and dip. The instrumentation team had documented several instances where pressure drops had caused control valves to respond sluggishly, affecting combustion control and emission readings. The operations supervisor put it this way: "The plant runs on instruments. When air pressure gets unstable, the instruments get nervous. And that makes us nervous."

Maintenance costs were climbing. The fixed-speed compressors started and stopped frequently, and every start put wear on the motor and airend. The maintenance team was replacing contactors and servicing airends more often than the manufacturer's schedule suggested. The plant's maintenance manager estimated that they were spending roughly 30% more on compressor maintenance than they had budgeted.

Kotech deployed the KOE-110(VSD) variable speed drive oil-injected screw compressor, specifically selected for its ability to match air supply to actual plant demand.

The KOE-110(VSD) is powered by a 110kW high-efficiency motor with an integrated variable frequency drive. Unlike fixed-speed units that run at 100% regardless of demand, the VSD technology adjusts motor speed to match the plant's real-time air consumption . At full capacity, the unit delivers up to 20 m³/min at 8.5 bar—enough to cover peak demand during soot-blowing cycles and high-load periods. During off-peak hours, the compressor ramps down to partial load, saving energy without compromising system pressure .

The variable speed drive also eliminates the pressure spikes and dips that had been troubling the plant's instrumentation. By continuously adjusting compressor output, the KOE-110(VSD) maintains a stable system pressure within a narrow band. This means pneumatic actuators and control valves see consistent air pressure, improving process stability.

The KOE series is built with a robust oil-injected screw airend, capable of operating in ambient temperatures up to 46°C and handling the dusty environment of a coal-fired power plant . The unit also features a modern touchscreen controller that integrates with the plant's control system, allowing remote monitoring and real-time performance tracking.