What is the role of centrifugal compressors in a power plant?

Centrifugal compressors are crucial in power plants, particularly in coal-fired facilities like the Paiton power plant. They supply compressed air, which supports essential operations. Their performance directly impacts the overall efficiency and operational expenses of the plant. Poor performance in these units can lead to significant energy waste and higher operational costs.

How is the efficiency of centrifugal compressors measured?

Specific Power Consumption (SPC) is a metric used to evaluate how efficiently a centrifugal compressor operates. It measures the power needed to produce a specific volume of compressed air. The study at Paiton power plant used SPC to compare different compressors, like Air Compressor SAC 2B, and identify those needing improvement. The lower the SPC, the more efficient the compressor.

What are the key steps to improve the performance of centrifugal compressors?

Several strategies can be implemented to enhance centrifugal compressor performance. These include maintaining low compressor room temperatures through improved ventilation and insulation, regularly cleaning inlet water filters, performing routine cleaning of cooling water pipes, ensuring preventive maintenance like vibration checking, and maintaining proper coolant flow rates as specified by the vendor. These measures directly target inefficiencies and help optimize the operation.

Where was the study on centrifugal compressor performance conducted?

The study focused on the Paiton coal-fired power plant Units 1 and 2. The plant utilizes several centrifugal compressors. The study aimed to assess the performance of these compressors, pinpoint inefficiencies, and propose solutions to improve their operation. The insights from the study can be used to enhance the efficiency of the plant and realize savings.

What are the benefits of optimizing centrifugal compressor performance?

By optimizing centrifugal compressor performance, power plants can achieve substantial energy savings and reduce costs. For example, improving the efficiency of a less efficient compressor, like SAC 1A, to match the performance of a better one, such as SAC 2B, can lead to significant annual energy savings. These improvements translate directly into lower operational expenses and increased profitability.

Centrifugal compressor with glowing energy lines symbolizing optimization and efficiency.

Optimize Your Power Plant: Proven Ways to Boost Centrifugal Compressor Performance

Samir D’Costa in Tech & Innovation December 2025 • 4 min read.

"Unlock hidden energy savings and improve efficiency in your coal-fired power plant. Learn practical strategies to maximize centrifugal compressor output."

In the power generation industry, efficiency and reliability are key to maximizing output and minimizing operational costs. Compressed air systems play a vital role in power plants, supporting critical functions. Among these systems, centrifugal compressors are essential, but their performance can significantly impact overall plant efficiency. Optimizing the performance of these compressors can lead to substantial energy savings and improved operational effectiveness.

Focusing on the Paiton coal-fired power plant Units 1 and 2, a study investigated the performance of centrifugal compressors to identify areas for improvement. The existing plant uses four centrifugal air compressor types to produce compressed air, consuming a substantial amount of electrical power. By analyzing the performance of these compressors, the study aimed to pinpoint inefficiencies and recommend strategies for enhancing their operation.

This article translates the findings of this study into actionable insights. Discover practical strategies for optimizing the performance of centrifugal compressors in your power plant, reducing energy consumption, and improving overall plant efficiency.

How to Evaluate and Improve Centrifugal Compressor Performance

Centrifugal compressor with glowing energy lines symbolizing optimization and efficiency.

To understand the performance of centrifugal compressors, the study used Specific Power Consumption (SPC) as a key metric. SPC measures the amount of power required to produce a specific volume of compressed air (kW/100 cfm). By measuring the air flow rate and power consumption of each compressor, the researchers calculated the SPC values and identified the most and least efficient units.

The study revealed significant performance variations among the compressors. The Air Compressor SAC 2B demonstrated the best performance with an SPC of 15.1 kW/100 cfm, while other compressors exhibited higher SPC values, indicating lower efficiency. This disparity highlighted the potential for improvement across the system.

Maintaining low compressor room temperature: Improve ventilation by repairing the existing system, installing ducting to remove hot air from electric motors, and insulating hot air ducts.
Regularly cleaning inlet water filters: Increase the frequency of filter checks due to the potential for dust accumulation from coal fly ash, especially on the air inlet side facing the coal conveyor.
Performing routine cleaning of cooling water pipes: Address pressure drops caused by dirt accumulation in the piping. The effectiveness of the air cooler can be assessed by measuring the temperature difference between the inlet and outlet cooling water.
Ensuring preventive maintenance: Implement preventive maintenance programs in accordance with the vendor's SOP. Conduct predictive maintenance activities like vibration checking, oil analysis, and temperature monitoring of the electric motor driving the compressor.
Maintaining coolant flow rate: Adhere to the coolant flow rates specified by the vendor, as outlined in Table 5 of the original study.

By implementing these strategies, power plants can optimize the performance of their centrifugal compressors, reduce energy consumption, and improve overall operational efficiency.

Realizing the Potential: Energy Savings and Cost Reduction

The study emphasized the potential for significant energy savings by improving the performance of less efficient compressors to match the best-performing unit (SAC 2B). For example, upgrading the SAC 1A compressor could result in substantial annual energy savings.

Improving the efficiency of centrifugal compressors not only reduces energy consumption but also translates into significant cost savings. By optimizing compressor performance, power plants can lower their operating expenses and improve their bottom line.

Optimizing the performance of centrifugal compressors is a practical and effective way to improve energy efficiency, reduce costs, and enhance the overall operation of power plants. By implementing the strategies outlined in this article, power plants can unlock hidden energy savings and achieve greater operational effectiveness.