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High Efficiency Gas Generator Installation

Upgrading On-site Power Generation to Reduce Natural Gas Fuel Consumption

Garment Manufacturing Facility, Bangladesh

The Challenge

The facility generated on-site electricity using a 900-kW gas-fired generator with a low electrical efficiency of 28% and a high specific fuel consumption of 0.33 m³/kWh. This resulted in high natural gas fuel expenses, substantial carbon emissions, and limited backup capacity.

The Solution

Upgraded to a 1,125-kW H-Series high-efficiency gas generator, which operates at an electrical efficiency of 43% and a reduced specific natural gas consumption of 0.22 m³/kWh. The new generator produces more electricity per unit of gas, cutting fuel demand and improving power supply reliability.

Process Optimization Flow

Process animation
1
Decommissioning

Safely decommissioned and removed the legacy 900 kW gas generator

2
Installation

Installed the 1,125-kW H-Series generator on reinforced concrete foundations

3
Distribution Connection

Connected gas supply line and tied electrical output into main busbars

4
Commissioning

Completed performance load trials, safety test runs, and operator training

Key Highlights

Efficiency Upgraded:

Thermal efficiency improved from 28% to 43%, extracting more electrical work per unit of fuel.

Natural Gas Reductions:

Saves 525,957 m³ of natural gas per year, protecting against gas supply volatility.

Capacity Boost:

Increased on-site generation capacity by 25% (900 kW to 1,125 kW), enhancing operational reliability.

Substantial CO₂ Offsets:

Reduces greenhouse gas emissions by 1,013 Tons of CO₂ equivalent annually.

Resource Impact Metrics

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Annual Natural Gas Saved (m³)
0
Annual GHG Emissions Saved (Tons)
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Upgraded Generator Efficiency (%)

Financial Performance

Total Investment
$339,361
Annual Savings
$209,585 / yr
Payback Period
1.58 Years

Live ROI Simulator

Adjust parameters to estimate savings for your facility

Est. Gas Saved
521,776 m³/yr
Est. Financial Savings
$182,622 / yr
Payback: 1.86 Years

Creating a Sustainable Future...