Operating Cost Calculation for Generator Sets

Operational Cost Analysis: Diesel vs Gas in Generator Sets

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Visual comparison of Genesal Energy generator sets highlighting operating costs for diesel and gas generator sets.
Choosing the right fuel type for a generator set is a critical decision that directly impacts operational costs and the efficiency of the power supply. The most common options are diesel generators and those powered by natural gas. This article provides a comparative overview of both systems, examining their advantages, disadvantages, and suitability based on the energy demands of each sector.

Factors Influencing the Operational Costs of a Generator Set

The operational cost of a generator set depends on more than just the fuel price. Other key factors include:

  • Fuel consumption according to load and operating hours.
  • Maintenance frequency and spare parts requirements.
  • Engine durability, depending on the type of fuel used.
  • Fuel supply availability and logistics at the project location.
  • Thermal performance and energy conversion efficiency.
  • Environmental regulations relating to fuel emissions.

These elements influence long-term investment, especially in industrial environments or critical applications where continuity of power supply is essential.

The most common options are diesel generators and those powered by natural gas.

Price Comparison: Diesel vs Natural Gas

Diesel has long been a reliable choice, but the price of natural gas is often more competitive, particularly for long-duration or continuous-use applications.

  • Diesel is subject to volatile pricing, influenced by global markets and specific fuel duties.
  • Natural gas generally offers more stable and predictable costs, making operational and financial planning easier.

Genesal Energy Diesel Generator Set and Fuel Fluid
Furthermore, long-term contracts with gas suppliers allow many industries to manage their operating energy costs more effectively.

Efficiency and Fuel Consumption: Diesel vs Gas Generators

Diesel generators typically deliver high efficiency under variable load conditions and quick start-up, making them ideal for short-duration or standby use. Their design allows for high power output within a short time frame.

In contrast, natural gas generators offer:

  • Lower specific fuel consumption in continuous, stable-load operations.
  • Cleaner combustion with fewer residues.
  • Improved thermal efficiency, particularly when used in combined heat and power (CHP) systems.
  • Lower noise and vibration levels, enhancing operational comfort.

Impact on Lifespan and Maintenance of Generator Sets

The type of fuel also affects equipment lifespan and maintenance needs:

  • Diesel engines require more frequent maintenance, including regular oil and filter changes and injector checks.
  • Natural gas engines generally allow longer intervals between servicing, with some models offering up to double the maintenance cycle compared to diesel engines.

However, gas engines require specific components, such as spark plugs and advanced air-fuel mixing systems, which demand specialised care.

Generator sets must meet new market challenges with the lowest possible operating cost and the highest commitment to sustainability.

Industrial Applications and Energy Demands Based on Fuel Type

The choice between diesel and gas depends on the specific power supply needs and application context:

  • Diesel generators: well-suited for emergency backup, quick starts, mobile use, and remote areas without gas infrastructure.
  • Gas-powered generator sets: ideal for continuous operation, thermal-electric cogeneration, and facilities with access to natural gas or biogas networks.

Industries such as manufacturing, logistics hubs, hospitals, data centres, public infrastructure, and agri-food facilities can benefit from either type depending on operational requirements.
Industry with High Energy Demand

Sustainability and Emission Reduction with Natural Gas

Natural gas is increasingly seen as a more environmentally friendly alternative to fuels such as diesel:

  • Significant reduction in NOx, CO₂, SO₂ and suspended particulate matter (PM10 and PM2.5), mainly generated by incomplete combustion in diesel engines.
  • Reduced impact on air quality, especially in urban or enclosed environments.
  • Lower odour and noise pollution.
  • Reduced risk of soil contamination in case of leaks.

In addition, using biogas or renewable natural gas brings operations closer to carbon neutrality, in line with European decarbonisation goals.

How to Choose the Best Option for Your Power Supply Needs

Deciding between gas and diesel depends on several key considerations:

  • Expected operating duration of the generator set (standby vs continuous).
  • Fuel availability and delivery logistics in the area.
  • Environmental restrictions and local regulations.
  • Climatic conditions and technical project requirements.
  • Available budget, covering both CAPEX and OPEX

For projects requiring long annual operating hours, gas is often more cost-effective in the long term. In contrast, for installations with sporadic use or urgent demand, diesel remains a robust and practical choice.

Trends and the Future of Fuel Use in Generator Sets

The shift towards a cleaner energy model is encouraging the adoption of alternative fuels, such as biogas, LPG, green hydrogen, or HVO blends (hydrotreated vegetable oil).

In addition, using biogas or renewable natural gas brings operations closer to carbon neutrality,

Hybrid systems that combine generator sets with renewable energy and battery storage are also gaining traction, offering more flexible and sustainable power solutions.

In the short to medium term, natural gas will remain a key solution for efficient and sustainable electricity generation, particularly in industrial settings and medium-to-large-scale projects.
Meanwhile, diesel generators will continue to play a vital role in applications requiring immediate response and proven reliability, such as hospitals, telecommunications, and emergency systems.
Hand touching a moss-covered log in a natural environment
Ongoing technological development, tighter environmental regulations, and the demand for flexible energy solutions will shape the sector’s future, where generator sets must meet new market challenges with the lowest possible operating cost and the highest commitment to sustainability.

Uninterrupted Power for Data Centers

Uninterrupted power for the New Era of Data Centers

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In an increasingly interconnected world, data centres have become the digital backbone of the global economy. The reliability of their power supply is crucial for their operation, as any interruption can lead to substantial financial losses and affect millions of users. In this context, Genesal Energy has established itself as a leader in emergency power generation, providing bespoke solutions for data centres across Europe and beyond.

Power that never fails

Our journey in the data centre sector is the result of more than 30 years of experience in designing and manufacturing generator sets for critical infrastructures such as data centers. Over time, we’ve strengthened our international presence with key projects in countries such as Norway, Germany, Spain and France, where our systems ensure power continuity in high-demand environments.

All our generator sets are ready to operate using renewable fuels such as HVO.

Some of the most notable examples include the supply of five generators in Norway and the installation of two units in Madrid, specifically designed to ensure the operational safety of data processing centres. In Germany, we developed generators with advanced noise reduction and emissions control systems, meeting the most stringent environmental regulations in the European market.
Data Center in extreme climate with Genesal Energy generator sets operating under snow and low-temperature conditions.

Engineering precision for a demanding sector

Every project is approached from an integrated engineering perspective, where customisation and reliability go hand in hand. Our generator sets for data centres feature:

  • Full compliance with Uptime Institute standards, supporting projects of up to 5250 kVA and enabling us to meet the demands of large-scale, high-availability facilities.
  • Fully tailored configurations: side-by-side layouts, radiator or air-cooled systems, custom acoustic enclosures, output switching for both critical loads and load banks via Powerlock connectors, direct generation at medium voltage (up to 15 kV), medium-voltage switchgear integration, and fire detection and suppression systems.
  • Redundancy systems to guarantee continuous operation under any circumstances.
  • Advanced automation, enabling real-time communication and seamless integration into Building Management Systems (BMS).
  • Emissions control technologies in line with the most demanding European regulations.
  • Custom testing protocols, including functional tests and simulations under real-world operating conditions to ensure performance in critical scenarios.

Technical Supervision of Electrical Systems in Data Centers

Sustainability and Ecodesign: Our commitment to the future

Our vision of industrial development is deeply rooted in sustainability. We are certified under ISO 14006, which supports our ecodesign approach, applied from the conceptual phase through to the final manufacturing stage. This methodology allows us to systematically reduce the environmental impact of our generators throughout their lifecycle.

All our generator sets are ready to operate using renewable fuels such as HVO (Hydrotreated Vegetable Oil), offering a practical solution for reducing CO₂ emissions without compromising performance.

Arquitectura sostenible con integración de vegetación en entorno tecnológico.

We also invest in R&D initiatives related to hydrogen as an alternative energy source and apply modular design and additive manufacturing techniques to increase efficiency and extend product life.

In addition, we align our products with European directives such as the Energy Efficiency Directive (EED) to ensure that our solutions are not only technically advanced but also aligned with long-term sustainability goals.

More than a supplier: A strategic partner

Our ability to offer the best lead times in high-power delivery is one of our key competitive advantages. In an environment where every minute counts, speed in implementation can be the difference between success and failure in a critical operation.

Our journey in the data centre sector is the result of more than 30 years of experience in designing and manufacturing generator sets for critical infrastructure.

We are involved in every stage of the project: from initial analysis and custom design to manufacturing, commissioning, and ongoing maintenance. This continuous technical support ensures that every energy solution meets the client’s exact needs.

Our approach, based on personalised attention and uninterrupted support, has made us a trusted strategic partner for the data centre sector.

Leadership in a growing market

Digital transformation is driving an increasing demand for reliable, efficient digital infrastructures. In this context, emergency power generation has become a cornerstone for the growth and expansion of data centres.

At Genesal Energy, we continue to demonstrate that our technology, experience, and commitment to sustainability are the guarantee of uninterrupted power for the most demanding environments in the new digital era.

Power Generator for Extreme Climates

Genesal Energy, delivering energy in the most extreme climates

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Securing energy supply in climates with extreme conditions, be it cold, heat or humidity, is a challenge that Genesal Energy is familiar with. In this case, the challenge of the project was to provide a solution in the extremely cold environment of Finland.

Faced with the need for reliable equipment to ensure the uninterrupted operation of the installation in the event of a mains power failure, we designed a generator set fully integrated into a 20 feet HC container, adapted to the demands of the environment and prepared to guarantee the continuity of the power supply. In addition, it had to be able to operate in low temperature conditions, be compact for easy transport and have the greatest possible autonomy. A technical challenge that we solved with a customised design.

Another key aspect of the design was the optimisation of space to increase the autonomy of the equipment.

To guarantee the correct operation of the unit in these climatic conditions, we incorporated a system of motorised grilles between the unit and the air outlet. These louvres allow air inlets and outlets to be closed, while the opening of an intermediate louvre creates a flow of hot air inside the container until the right temperature is reached. It is equipped with a heating recirculation pump to guarantee start-up in extreme conditions. At the same time, customised soundproofing ensures that the noise level is extremely low.

Another key aspect of the design was the optimisation of space to increase the autonomy of the equipment, so we designed a customised fuel tank with a capacity of 2,000 litres, with a double steel wall and strategically located at the entrance of the container. Its rectangular format allowed us to make better use of space without compromising accessibility.

Our Engineering Solution

Our team designed a solution totally adapted to the customer’s needs and focused on solving two problems: on the one hand, withstanding low temperatures, and on the other hand, increasing the autonomy of the unit as much as possible.

Features

  • Large capacity tank. 2.000 litres double walled (Steel-steel).
  • Recirculating heating pump.
  • Integrated silencer in container, GSI 490 (-30 dB).
  • 630 A, 3-pole, LSI circuit breaker.
  • Battery protection box with ventilation.
Mobile Generator Set for Wind Turbine Blade Recycling

Genesal Energy promotes sustainability in wind farms with a mobile generator set for the recycling of turbine blades.

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The energy transition and the fight against climate change have boosted the development of wind energy, making it one of the main renewable sources worldwide. However, this progress brings with it a significant challenge: the efficient recycling of wind turbine blades.

With an average lifespan of 20 years – extendable to 25 with proper maintenance – most components of a wind turbine are recyclable. However, blades present a unique challenge due to the composite materials used in their manufacture: glass & carbon fibre and resins. These materials are complex to separate, which raises costs and makes large-scale recycling difficult.

Genesal Energy has taken a step forward in search of sustainable solutions to this challenge. In collaboration with GDES Wind – a company specialised in the maintenance and inspection of blades in wind farms – we designed and installed a 45 kVA mobile generator set to power a machine specialised in the recycling of wind turbine blades. This equipment cuts the blades using diamond wire, offering an efficient and environmentally friendly alternative. The pieces are then efficiently treated as waste, generating mortar or useful pieces for new applications such as planters, canopies or pieces of furniture.

With this project, Genesal Energy reinforces its commitment to sustainability and the circular economy.

This genset – which complies with Stage V emissions standards – not only ensures a low environmental impact but also provides autonomy of up to 35 hours at 100% load thanks to its 350-litre tank. It is also equipped with a socket panel to power auxiliary tools, extending its functionality and operational efficiency.

A growing challenge in the wind power industry

Although most blades are currently reused in repowering processes or converted into architectural structures such as bridges or bicycle racks, this strategy will not be sufficient in the long term. According to WindEurope, up to 5,700 wind turbines per year will be dismantled in Europe from 2030 onwards, which means an increasing volume of retired blades that will require innovative solutions for recycling.

Grupo electrógeno móvil para eventos con diseño ligero.

Image 1: The trailer-mounted genset inside the customer’s warehouse.

The equipment designed by Genesal Energy to power the GDES Wind solution represents a key step in this direction, aligning with the principles of the circular economy and offering the wind sector an indispensable tool to sustainably manage the dismantling of wind turbines.

With this project, Genesal Energy reinforces its commitment to sustainability and the circular economy. We continue working to make energy not only cleaner, but also more socially responsible.

Features

  • Supply: 2600mm soundproofed canopy on trailer.
  • Stage V emissions-compliant engine.
  • 350L base frame inserted fuel tank.
  • Control panel: ComAp AMF 25 InteliLite4.
  • Socket panel.