Energy-efficient condensate pumping upgrade
Reference Kokkolan Energia
At a glance
Innomotics helped Kokkolan Energia improve the efficiency, reliability, and sustainability of its condensate pumping process through a turnkey modernization solution featuring an IE5 permanent magnet motor, optimized pump technology, and variable-speed control.
Challenges:
- Modernize an aging condensate pumping system based on fixed-speed operation and throttling control
- Improve energy efficiency and reduce operating costs
- Enhance process control and operational flexibility
- Support long-term sustainability and plant performance goals
Solutions:
- Installed a 90 kW IE5 permanent magnet motor (FS280)
- Replaced the existing pump with an optimized pump design
- Implemented inverter-based variable-speed control
- Delivered a complete turnkey package including engineering, installation, and commissioning
Outcome:
- Reduced energy consumption and lower operating costs
- Improved process control and operational flexibility
- Increased system reliability and long-term availability
- Simplified project execution through a single-source delivery
- Reliable local service support and fast access to spare parts
The Challenge – Condensate Pumping Modernization
Kokkolan Energia produces and distributes steam, district heating, and electricity throughout the Kokkola region in Finland. Operating two combined heat and power (CHP) plants and holding stakes in several additional production facilities, the company continuously seeks opportunities to improve operational efficiency and sustainability.
As part of this effort, Kokkolan Energia identified the need to modernize its condensate pumping process. The existing system, consisting of a direct-on-line motor, pump, and throttle valve, provided reliable service for many years but no longer delivered the level of energy efficiency, process control, and operational flexibility required for modern plant operation.
The solution – A turnkey upgrade for optimized process performance
To meet these objectives, Innomotics and local Advanced Partner Jukkola Systems Oy delivered a complete turnkey modernization package designed specifically for the application.
The solution included a 90 kW IE5 permanent magnet motor (FS280), a newly optimized pump, inverter-based speed control, and all related mechanical installation and commissioning work. Replacing the fixed-speed system with a variable-speed solution enabled the pumping process to be matched more precisely to operational demand, improving both efficiency and controllability.
By providing the entire upgrade as a turnkey delivery, the project was streamlined from engineering and installation through to commissioning, ensuring smooth implementation and minimizing complexity for the customer.
Result
The modernization provided Kokkolan Energia with a more energy-efficient and adaptable condensate pumping system that supports its long-term operational and sustainability goals.
The project demonstrates how a carefully engineered combination of a high-efficiency permanent magnet motor, optimized pump technology, and variable-speed control can deliver significant operational benefits while simplifying implementation through a single-source turnkey approach.
We selected Innomotics & Jukkola because they offered the complete package: highly efficient motor and drive technology, strong local process expertise, and the ability to deliver the entire project from engineering through to commissioning. The implementation was smooth, with minimal disruption to our operations, while the availability of local service support and spare parts gives us confidence in the long-term reliability and performance of the system.
Tommi Korpi, Production Director, Kokkolan Energia