Engineering, Sustainability, and Innovation: Key Pillars for Meeting European Taxonomy Standards

European Union flags waving in Brussels.

“The transition to a low-carbon economy requires a fundamental transformation in the way businesses operate, and the EU Taxonomy is essential for guiding and supporting this transformation.” – European Investment Bank (EIB)

Energy transition is at the heart of European policies, with the clear aim of reducing greenhouse gas emissions and promoting sustainability through activities aligned with the European Union’s environmental objectives. However, the generator sector, often perceived as having a significant environmental impact due to the use of fossil fuels, has been excluded from the European Taxonomy for sustainable economic activities. This situation has sparked a debate about the role that power generators can play in the energy transition.

In this article, we explore how the generator sector, particularly emergency generators, cannot only meet the expectations of the European Taxonomy but also lead the way in the energy transition towards a more efficient and environmentally friendly industry.

Let’s Start from the Beginning: What is the European Taxonomy?

The European Taxonomy is a classification system designed to help identify and guide investments towards environmentally sustainable economic activities. This classification enables investors, businesses, and policy makers to make informed decisions about which activities can contribute to the EU’s climate and sustainability goals, aligning with the European Green Deal.

Taxonomy establishes a set of key pillars that define what qualifies as a sustainable economic activity and the criteria that must be met for an activity to be considered aligned with the EU’s environmental targets.

These pillars, essential for ensuring that investments flow into sectors that genuinely contribute to a greener and more sustainable future, are as follows:

  • Climate Change Mitigation: This principle advocates for the development of activities that help to reduce greenhouse gas (GHG) emissions, which are responsible for global warming. Activities that contribute to climate change mitigation include the adoption and expansion of renewable energy sources and those that enhance energy efficiency in buildings, industry, and transport.
    Additionally, mitigation involves transitioning to sustainable mobility models, such as electric vehicles, and promoting agricultural and land-use practices that sequester carbon instead of releasing it, such as regenerative agriculture or reforestation.
  • Climate Change Adaptation: This refers to activities that increase the resilience of natural and human systems to the impacts of climate change. It is one of the most crucial pillars, especially given that the effects of climate change are already evident and will continue to intensify in the coming decades.
    Adaptation activities include improving urban infrastructure to make it more resistant to extreme weather events such as floods or heatwaves. Also included in this category are initiatives that promote sustainable water management and the adaptation of agriculture to new climatic conditions, with drought-resistant crops or more efficient irrigation techniques.
  • Protection and Restoration of Ecosystems and Biodiversity: The loss of biodiversity and the degradation of natural ecosystems are among the most severe consequences of climate change. For this reason, the Taxonomy encourages activities that help preserve existing ecosystems and restore damaged ones, contributing to the long-term sustainability of life on Earth.
    This includes reforestation projects, the creation of protected areas to conserve natural habitats and endangered species, as well as sustainable agricultural practices that protect soils and water bodies. Furthermore, the protection of marine ecosystems and the restoration of aquatic habitats are also essential for maintaining biodiversity and ecosystem services such as water purification and climate regulation.
  • Circular Economy: This pillar promotes activities aimed at minimising waste and maximising the reuse of resources, such as recycling, material reuse, and the design of products that are easily recyclable or require fewer resources for production.
    However, the circular economy is not only about waste reduction—it is also linked to reducing the extraction of natural resources by promoting the recovery of materials from discarded products, thereby reducing pressure on ecosystems and minimising the carbon footprint.

Wind farm at sunset, symbolizing the energy transition and sustainability in line with European Taxonomy standards.

For an activity to be considered aligned with the European Taxonomy, it must meet a set of specific technical criteria that significantly contribute to the objectives mentioned. These criteria focus not only on activities that generate a direct positive environmental impact but also on the principle of “Do No Significant Harm” (DNSH) to other objectives. This means that, in addition to positively contributing to one of the pillars, an activity must not harm other sustainability aspects, such as biodiversity or human health.

This comprehensive approach ensures that investments and activities aligned with the Taxonomy are not only environmentally responsible but also promote sustainable economic development that is socially inclusive and does not cause long-term damage to natural resources.

Why Should This Not Be the Case? The Crucial Role of Power Generators

The exclusion of the generator sector from the eligible activities under the Taxonomy could overlook the fundamental role these machines play in the energy transition. Emergency generators are essential for ensuring the security and reliability of electricity supply. As the integration of renewable energy sources into the power grid increases, so does the need to secure a stable and reliable energy supply. Renewable energy sources such as solar and wind are inherently variable, which can lead to fluctuations in electricity generation.

In this context, emergency generators act as a safeguard for the power grid, rapidly compensating for any drop in generation and maintaining grid stability.

Furthermore, technological advancements have made it possible to design emergency generators that use sustainable fuels, such as HVO (hydrotreated vegetable oil), and emission reduction technologies. Solutions such as gas post-treatment systems, including diesel particulate filters (DPF), selective catalytic reduction (SCR), and urea injection, enable generators to operate with a significantly lower carbon footprint, aligning with the EU’s sustainability goals and contributing to the transition to a low-carbon economy. Additionally, the limited use of these generators—typically operating only a few hours per year—minimises their environmental impact, as their emissions are negligible compared to continuous energy generation sources.

Moreover, new innovations enable generators to be more fuel-efficient and minimise emissions. The adoption of technologies such as thermal insulation systems enhances not only safety but also the operational efficiency of these generators. This makes emergency generators an integral part of sustainable infrastructure, ensuring grid stability while supporting the integration of renewable energy and providing reliable backup power when it is most needed.

A Case Study from Genesal Energy

At Genesal Energy, we have developed several projects that serve as clear examples of how the generator sector can adapt to the sustainability standards imposed by the European Taxonomy. Recently, we carried out a project that demonstrates that, through engineering, it is possible to integrate solutions into these machines that reduce their environmental impact without compromising their reliability and efficiency.
Workers manufacturing and inspecting a generator set, with a detailed view of its engine.

A key aspect of this project was compliance with highly stringent emissions regulations in Belgium. To achieve this, advanced gas post-treatment systems were incorporated, including diesel particulate filters (DPF) and selective catalytic reduction (SCR) with urea injection. These technologies minimise pollutant emissions to the maximum, aligning with the most demanding environmental standards.

Additionally, the generator design included solutions that optimise energy efficiency and ensure safety in harsh environments. Custom load steps were implemented to improve energy consumption, and fuel heaters were added to ensure operability in low temperatures with ATEX (Explosive Atmosphere) certification for maximum safety. Leak detection systems and liquid collection trays were also installed, reinforcing environmental protection.

<blockquote class=”bq-border”>To ensure efficient and safe operation, the project incorporated an independent electrical room equipped with a remote control panel, allowing remote management of the generators.</blockquote>

Medium-voltage grounding resistors and a medium-voltage switchgear with automatic circuit breakers were also added to integrate with the plant’s installation requirements.

Finally, special attention was given to reducing acoustic impact, incorporating soundproofing solutions to keep noise levels below 80 dB at 1m under normal operating conditions, significantly reducing noise emissions. Motorised grilles were also included to isolate the generators from the environment during inactivity periods, optimising efficiency and extending their lifespan.

This case demonstrates that, thanks to new technological solutions, sustainability can be a fundamental aspect of the generator sector, enabling compliance with the strictest European Taxonomy and environmental regulations while contributing to the transition to a cleaner and more efficient energy model.

 

Most Common Failures in Generator Sets

Technician performing maintenance on a generator set to prevent failures and ensure proper operation.
Generator sets are essential tools for energy supply in various situations. However, they can experience failures that affect their performance and reliability. It is crucial to understand the main causes of these failures and how to prevent them.

Proper maintenance can extend the lifespan of the generator set and ensure its proper operation.

Main Causes of Failures in Generator Sets

Generator sets can suffer from various failures, primarily due to a lack of maintenance or improper use. Below are the most common causes that can affect their performance.

Fuel Issues

One of the most frequent problems is related to fuel. Running out of fuel or using the wrong type can prevent the generator from starting. Some common causes include:

  • Lack of fuel: The generator will not function if the tank is empty.
  • Incorrect fuel type: Using an unsuitable fuel can damage the engine.

Battery Failures

The battery is essential for starting the generator set. Its failures can be caused by:

  • Loose connections: Poorly connected cables can prevent startup.
  • Discharged battery: Particularly problematic if the generator is not used frequently.
  • Sulfate accumulation: Can obstruct contacts and prevent proper operation.

Oil Leaks

Oil leaks affect both the efficiency and safety of the generator. If unchecked, they can lead to fires. Regular oil level inspections are essential to prevent this issue.

Diagnosis and repair of a generator set failure, including temperature measurement and electrical adjustment.

Switches and Fuses

These components are crucial for the protection of the generator set. Failures can result in unexpected shutdowns. Regular maintenance and timely replacement of damaged fuses or switches are vital.

Insufficient Energy Production

A lack of power output can have several causes, such as:

  • Overload: Connecting too many devices can exceed the generator’s capacity.
  • Connection system issues: Checking cables and connections is essential for proper operation.

Air Leaks in the Fuel System

Air infiltration into the fuel system is a common issue when the generator remains inactive for extended periods. It leads to difficulties in starting. Proper system maintenance can prevent this situation.

Technician performing maintenance on an industrial generator set.

Electrical Panel Failures

The electrical panel can experience failures due to prolonged use or vibrations. Generally, replacing the faulty component is required to restore its function.

Exhaust System Issues

The exhaust system must function correctly to prevent combustion gases from entering the generator’s housing.

Regular checks of silencers and joints are vital to ensuring safe generator operation.

Maintenance and Failure Prevention

Technician adjusting connections in the electrical system of a generator set.

Recommendations for Regular Maintenance

Preventive maintenance should include scheduled activities to ensure the generator operates correctly. Key recommendations include:

  • Regular oil changes and replacement of air and fuel filters.
  • Scheduled inspections to detect and resolve issues before they become major failures.
  • Cleaning components to remove dirt and debris that could affect performance.

How to Prevent Overheating

Overheating can cause severe engine damage. Implementing preventive measures is essential.

  • Importance of the Air Filter: A clean air filter allows the proper airflow to the engine, which is essential for efficient combustion and preventing overheating. Regularly inspecting and replacing the air filter is recommended.
  • Checking the Coolant Level: Maintaining the correct coolant level in the cooling system prevents overheating. Inspecting the system for leaks or decreasing fluid levels is crucial.

Strategies to Prevent Damage

Taking precautions to protect the generator can prevent severe long-term damage. The following strategies are recommended:

  • Protecting the Generator from Moisture: It is essential to keep the generator in a dry environment. Moisture can cause corrosion and electrical failures. Using appropriate covers and keeping the storage area clean and dry is crucial.
  • Avoiding Generator Overload: Overloading the generator beyond its designated capacity can damage internal components. Understanding the generator’s rated power and controlling the number of connected devices is essential.

Technical Aspects and Professional Consultancy

Proper generator set operation requires not only good maintenance but also the evaluation of fundamental technical aspects.

Professional consultancy ensures that generators operate under optimal conditions and that technical issues are efficiently resolved.

When to Consult a Technician

It is essential to know when to seek professional assistance to ensure the generator’s performance. Key situations include:

  • Recurring failures: If the generator frequently experiences issues, a technician can diagnose the root cause.
  • Poor performance: If the generator is not producing the required energy, professional intervention is crucial.
  • Advanced maintenance: For inspections that require in-depth technical knowledge, hiring a specialist is advisable.

Genesal Energy technician inspecting a generator set.

Importance of a Properly Sized Generator Set

Choosing a well-sized and reliable generator set is fundamental to ensuring optimal performance. A high-quality generator offers significant advantages, including:

  • Greater durability: Recognised brands manufacture generators with high-quality materials, making them more resistant.
  • Lower maintenance costs: A good generator includes high-quality components that reduce the risk of failures and repair costs.
  • Better performance: These units are generally more efficient in power production, leading to lower fuel consumption.

How to Extend the Generator’s Lifespan

Proper maintenance and handling of the generator are essential to prolong its lifespan. Several strategies can be adopted, including:

  • Scheduling regular maintenance: Regular inspections help identify problems before they become major failures.
  • Using quality fuel: Suitable fuel improves engine performance and reduces internal component wear.
  • Controlling the operating environment: Keeping the generator in a dry and well-ventilated location enhances its longevity and reduces the risk of corrosion.

Electric Generator vs Genset: Key Differences

Genesal Energy technician inspecting and adjusting the control panel of an industrial generator set.

What is the difference between an electric generator and a generator set? Both devices have the same objective: to provide electrical power. This is why the two concepts are often confused.

Technically, an electric generator is a component designed to convert mechanical energy (motion) into electrical energy. In contrast, a generator set is a complete system that integrates an electric generator and an internal combustion engine, allowing it to function autonomously.

Defining the Concepts

Understanding the fundamental concepts of electric generators and generator sets is essential for correctly using both terms.

Electric Generator

An electric generator is a device that transforms mechanical energy into electrical energy. This transformation occurs through a rotating system where a rotor generates a magnetic field that induces a current in the stator.

Electric generators are commonly used in power plants to generate electricity that can be stored and consumed later. They require an external power source, such as diesel engines (which would form a generator set) or steam turbines, to provide the necessary mechanical energy.

Power generation plant with cooling towers and electrical transmission lines.

Generator set

A generator set combines an internal combustion engine with an electric generator (also known as an alternator) in a single unit. This equipment is self-sufficient and designed to generate electricity in emergency situations or locations without access to the electrical grid.

When activated, the engine burns fuel to produce mechanical energy, which the alternator then converts into electrical power, ensuring an immediate and reliable energy supply.

Why Is There Confusion Between the Terms?

In everyday use, many people think of an electric generator as a compact unit, such as portable models used in homes or small businesses during power outages. These devices, typically with a capacity of up to 10 kVA, are accessible and practical, ideal for powering household appliances or basic tools.

However, this concept is incorrect. These small units are not just electric generators but small generator sets, as they integrate both an internal combustion engine and an electric generator in a single self-contained unit.

On the other hand, the term generator set is often associated with large industrial electric generators, like those manufactured by Genesal Energy. These units are designed for large-scale projects, with power outputs ranging from 10 kVA to several MVA, and are essential in industrial, healthcare, energy, and critical infrastructure sectors.

This misuse of terminology can lead to confusion when selecting the right equipment or understanding how it functions.

Genesal Energy facilities, with units in the assembly and testing process.

How to Choose the Right Equipment

The choice between an electric generator (or rather, a small generator set) and an industrial generator set depends on the intended use:

  • Small domestic or commercial applications: Low-power portable units (up to 10 kVA) are usually the best option. Although they are commonly called electric generators, they are technically compact generator sets.
  • Industrial or large-scale applications: In these cases, it is necessary to opt for industrial generator sets with higher power capacities, capable of ensuring a continuous and reliable power supply, like those in our catalogue.

Although “electric generator” and “generator set” are often used interchangeably in everyday language, it is important to understand their technical differences and applications.

In essence, every generator set contains an electric generator, but not all electric generators are complete generator sets.

Additive manufacturing
and the road
to sustainability

Sustainability has become a priority in all industrial sectors. The need to balance economic growth with environmental preservation is driving the search for innovative technologies to reduce environmental impact at all stages of the industrial process – including product manufacturing.

In this context, additive manufacturing is emerging as an innovative and effective solution for its potential to reduce the amount of raw materials required and waste generated, to the extent that it is already considered one of the fundamental pillars of 4.0 Industry.

What exactly is additive manufacturing?

Traditionally, products are made by removing material from a solid block through various processes, such as cutting, drilling or enamelling. In contrast to this process of ‘subtractive manufacturing’ is ‘additive manufacturing’, where the production of goods is done through the aggregation of material coatings. This addition is done layer by layer until the shape previously defined in a digital model is achieved, so that only the exact amount of material needed to create the part is used.
Engineers working on 3D component design, applying additive manufacturing technology.

Fundamental principles
of additive manufacturing

The starting point for any additive manufacturing piece of work is the digital design of the part. Three-dimensional models are translated into two-dimensional layers that can be built up successively using a 3D printer. The materials used vary widely and include plastics, metals, ceramics, composites and even biomaterials.

The main current additive
manufacturing technologies are:

  •  Fused deposition modelling (FDM): uses heated and extruded thermoplastic filaments to build the part layer by layer. It is one of the most accessible and common technologies, especially in domestic use and prototyping.
  • Selective Laser Sintering (SLS): Uses high-power lasers to fuse powder particles of material, such as plastic or metal, to form solid structures. It is ideal for complex and durable parts.
  • Steriolithography (SLA): Solidifies photosensitive liquid resins layer by layer using an ultraviolet laser. Produces parts with great detail and high quality surface finishes.
  • Direct Metal Laser Sintering (DMLS): Designed for metallic materials, this technology fuses metal powders using lasers. It is widely used in the aerospace and medical industries for its ability to create high-precision, high-strength parts.
  • Binder Jetting: Uses a binding agent to bind layers of powdered material together, which are then solidified by secondary processes such as sintering. It is an efficient technology for mass production of complex parts.

Sustainable industry focused on efficiency and the environment.

The impact of additive
manufacturing on sustainability

Reducing material waste

One of the most obvious benefits of additive manufacturing is the drastic reduction in material waste compared to the traditional subtractive process. For instance; when manufacturing metal components by milling, up to 90% of the raw material is wasted; whereas, with additive manufacturing, this waste can be almost non-existent. This advantage is particularly relevant in the manufacture of high-cost components, such as titanium in the aerospace industry.

Design optimisation and energy efficiency

The ability to manufacture complex geometries without great costs allows the design of optimised components that would not be feasible using traditional techniques. For example, lightweight lattice structures created through additive manufacturing offer an optimal weight-to-strength ratio, reducing energy consumption during the use of the final product.
3D prototyping lab and machining process in industrial manufacturing.
Furthermore, the weight reduction often achieved through additive manufacturing – either through the new designs allowed or through the use of a new material for the manufacture of components – can translate into substantial fuel savings in key sectors such as freight transport. This, in turn, means reducing CO₂ emissions and thus the impact on climate change.

Local and decentralised production

Another advantage of additive manufacturing is on-demand production close to the point of use. This decentralisation drastically reduces the need for transportation and warehousing, two of the main contributors to greenhouse gas emissions in traditional supply chains. In addition, the ability to manufacture parts on-site in remote areas reduces dependence on a complex logistics system.

Use of recycled materials

The development of more sustainable materials is driving the adoption of additive manufacturing in contexts such as eco-design. Bioplastics such as PLA (polylactic acid), derived from biological raw materials such as corn, represent viable alternatives to petroleum-based plastics.

Similarly, the use of recycled materials is also on the rise, allowing 3D printed products to contribute to the advancement of the circular economy.

Genesal Energy’s commitment
to additive manufacturing

Although Genesal Energy had already tested additive manufacturing in the context of the NextFactory project, it was not until 2024 that it took the final step towards integrating this technology into its industrial processes. As part of a project co-funded by the Regional Goverment, the company has acquired a state-of-the-art 3D printer with the aim of reducing the carbon footprint of its generator sets.

One of the first initiatives has been the application of this technology in the design of the company’s standard line of generator sets. After appropriate calculations and various modelling and material application tests, it has been demonstrated that the use of 3D printed components not only reduces material waste, but also optimises the performance of the equipment. The results have been so promising that we plan to expand the use of these techniques to the rest of the range in the future.

On top of the environmental benefits, this technology also opens up new possibilities for product customisation and the manufacture of complex parts that improve the operational efficiency of gensets. This reinforces Genesal Energy’s commitment to innovation and sustainability in the customised energy sector.

Project co-financed by the Xunta de Galicia.

Biogas and biomethane: key players in the circular economy and the energy transition

Aerial view of a wastewater treatment plant, key to biogas and biomethane production in the circular economy.

“Biogas and biomethane stand out within the bio circularity ecosystem for their ability to offer immediate and viable solutions in the ecological transition.”

Margarita de Gregorio, CEO of Biocirc.

One of the fundamental aspects in the fight against climate change is the economy. Currently, the linear economy, based on the ‘extract, produce, consume and dispose’ model, contributes significantly to the environmental crisis by prioritising economic profit and ignoring sustainability. This way of acting leads to a depletion of natural resources, the generation of large amounts of waste and the emission of greenhouse gases.

It is therefore crucial to move towards what is known as the ‘circular economy’. This new economic system promotes the management and recovery of waste to keep it in the production cycle for as long as possible. This helps to reduce both the consumption of raw materials, and the amount of waste generated.

The part of the circular economy that addresses the production cycle of those sectors whose raw materials are of biological origin is known as bio circularity. This approach makes it possible to replace raw materials of fossil origin with others of renewable origin, while at the same time reusing organic waste, contributing to the decarbonisation of multiple sectors and to a more sustainable management of waste.

In this context, biogas and biomethane play crucial roles thanks to their ability to regenerate natural systems and contribute to the energy transition. But first things first…

What is biogas and biomethane?

Cows grazing in front of a biogas plant in a rural setting.
Biogas is a renewable, carbon-neutral gas produced from the anaerobic digestion of organic matter, i.e. from the biodegradation of organic waste in the absence of oxygen. Thus, during this process, which takes place in an airtight tank or digester, the carbohydrates, proteins and lipids present in the waste are broken down by a series of bacteria, releasing a mixture of gases known as biogas. In addition, digestate, a biosolid with high fertiliser capacity, is also obtained as a by-product.

The composition of biogas varies depending on the waste used as raw material or substrate, although it is usually between 50-75% methane (CH₄) and 25-45% carbon dioxide (CO), with small amounts of other gases such as hydrogen sulphide (H₂S), ammonia (NH₃), volatile organic compounds (VOC) and water vapour.

Of the aforementioned, the methane concentration is the most relevant factor, as it determines the calorific value of the fuel. 1 m³ of biogas with a composition of 50% CH₄ would produce 5 kWh of energy, replacing 0.50 m³ of natural gas; whereas, if the methane composition is raised to 65%, the same cubic metre of biogas would produce 6.40 kWh of energy, replacing 0.65 m³ of natural gas. [These calculations are based on the lower calorific value of natural gas (10.83 kWh/m³)].

On the other hand, before being used as energy, biogas must undergo a process to remove impurities that can cause damage to the installations and reduce the efficiency of the system. H₂S, for example, is highly corrosive and can damage motors, turbines and other equipment if it is not removed adequately. In addition, water vapour reduces the calorific value of the biogas, which is why it is essential to separate it.

After this process, biogas is suitable for use as a fuel in the production of heat in gas boilers or in the generation of electricity through combustion engines, among others.

However, to broaden its applications, biogas can undergo an additional process, known as ‘upgrading’, for the production of biomethane. This process involves the almost total elimination of CO and other residual compounds, raising the methane concentration to more than 95%. The result is a renewable gas with energy-characteristics comparable to fossil natural gas.

The advantage of biomethane over biogas lies in its higher calorific value and its ability to replace natural gas, thanks to its high methane content. This allows biomethane to be injected directly into the existing gas grid, extending its use to sectors such as transport, industry and residential. Its integration into existing infrastructure makes it an immediate decarbonisation solution, especially compared to other renewable gases, which require the development of specific infrastructures. Moreover, if biogenic CO₂ capture is carried out during its production, biomethane can achieve negative carbon emissions.

Opportunities in the valorisation of organic waste

The dual benefits of biogas and biomethane – as a renewable energy source and a climate mitigation tool – are sufficient to take them into account in the transition to a sustainable, low-carbon energy system. But their use has advantages that go far beyond the simple production of energy, as the production of these biofuels is also emerging as an innovative and sustainable solution for the valuation of organic waste produced by various economic sectors.

Currently, part of this waste is managed inefficiently and it often ends up polluting soil, water and the atmosphere itself, which has a high environmental impact. In this context, anaerobic digestion can play a key role in managing waste such as the following:

  • Livestock sector: Livestock waste, such as manure, slurry, animal bedding and cleaning water, can lead to the incorporation of heavy metals into the soil, the pollution of water by excess nitrates or the emission of ammonia into the atmosphere if not properly managed.
  • Agricultural sector: Agricultural residues, including pruning, wood and herbaceous waste, are often inefficiently managed through indiscriminate burning or abandonment, contributing to environmental degradation, fires and the spread of pests.
  • Food sector: Slaughterhouse rejects, waste from the fishing industry, organic waste and liquid by-products from the dairy industry, or fruit or vegetable scraps that are not reused can end up rotting in landfills, where they emit methane, a gas with a warming potential 21 times greater than CO₂.
  • Municipal Solid Waste (MSW): The organic fraction of municipal solid waste (MSW), such as food waste or domestic pruning, can be biodegraded and reused to produce energy or natural fertilisers. This process also contributes to achieving the recycling targets set out in Law 7/2022 on Waste and Contaminated Soils, which allows further progress towards a circular economy by reducing municipal waste.
  • Wastewater Treatment Plants (WWTP): Sludge generated in wastewater treatment represents a costly challenge for WWTPs, as its management can account for up to 50% of operational costs. Anaerobic digestion can reduce the volume of sludge and generate biogas, turning a problematic waste into a renewable source of energy.

Biogas plant facilities surrounded by agricultural fields and waste management areas.
In other words, biogas and biomethane stand out not only as renewable energy sources and tools for decarbonisation, but also for their ability to reduce dependence on fossil fuels, bringing greater flexibility to the energy system.

Their ability to decarbonise sectors that are difficult to electrify is particularly valuable in the transition to a cleaner energy model.

 

In addition, anaerobic digestion technology is already well established, and the necessary infrastructure is available, making biogas and biomethane an immediate solution.

A crucial added value of these sources is their contribution to the circular economy, since, as we have seen, they allow the revalorisation of organic waste generated by various sectors. Not only do they significantly reduce waste, but they also create new opportunities in sustainable and circular value chains, especially on a small scale and in rural environments. This approach favours the dynamisation of these areas, while contributing to the fulfilment of the objectives of the bioeconomy in Spain, promoting a more balanced and sustainable model of economic development.

Diagram of the biogas and biomethane production and utilization process.

Picture 1. Biogas value chain

Biogas and Biomethane Genesal Energy gensets

Genesal Energy is fully aware of the enormous potential of renewable gases and the importance of the circular economy. We participate in projects that promote the valorisation of waste to transform it into valuable resources such as biofuels. These gases can be used on gas power gensets, taking a further step towards a sustainable energy model by not only using a renewable source instead of conventional fossil diesel, but also a source generated from the reuse of waste that would otherwise end up representing an environmental problem.

Hand in hand with FACSA, SMALLOPS, AIMEN and UVA, we are part of the ENEDAR project – ‘Improving the energy efficiency and sustainability of wastewater treatment plants through the valorisation of WWTP sludge’, financed by the Ministry of Science, Innovation and Universities and the European funds NextGeneration UE/PRTR.

Genesal Energy is here responsible for designing and validating the operation of a generator set powered by fuels from the anaerobic digestion of sewage sludge from a pilot plant; reaffirming our commitment to the energy transition and the creation of immediate and practical solutions for a sustainable future.

How to connect a genset in industrial or commercial installations

Technician connecting a generator in an industrial setting
Connecting a generator set to the power grid of an industrial or commercial facility is a key process to ensure a continuous supply during grid failures.

In sectors such as industry, hospitals or data centres, where energy is vital, it is essential to know the correct steps and methods to make a safe and efficient connection.

Basic concepts for the connection of a generating set

Before proceeding with the installation of a generating set, it is essential to carry out an exhaustive analysis of the electrical demand of the installation. This involves calculating the power required for critical equipment, verifying current safety regulations and correctly sizing the system components.

Each installation has specific needs, so it is essential to design a system that guarantees a reliable supply and complies with protection standards.

Key requirements include

  • Critical load assessment: Identify which areas and equipment need continuous supply in the event of mains failure.
  • System planning: Determine the type of generator set, switchgear capacity, and the voltage and frequency to be supplied.
  • Regulatory compliance: Ensure that the design of the installation complies with low voltage regulations and that all relevant safety measures are in place.

General view of a shopping center where energy is essential

Methods of connection of a generating set to the mains

Direct connection of the generating set to the grid

To ensure efficient switching between the mains and the generating set, it is essential to use a switchboard. This device automatically detects any mains failure and switches over to the genset without manual intervention (in case of an automatic system). The ATS (automatic switchboard) is the key element in installations where the continuity of the power supply is critical, as it ensures that the change of the power supply is carried out without cuts or with a minimum cut-off.

Learn more about the mains/generator switching process here.

The installation process of an ATS includes the configuration of its parameters so that, in the event of any mains failure, the system can start the generator and transfer the load instantaneously. This type of automation is essential in sectors such as hospitals, data centres or telecommunications infrastructures, where any interruption may be unacceptable.

Connecting a three-phase genset

In high-demand industrial environments, three-phase gensets are often used to ensure a balanced power distribution. These generators operate using three phases of alternating current and can be connected in two main configurations: star or delta.

  • Star connection: In this scheme, all phases are connected to a single neutral point, which facilitates the balancing of distributed loads.
  • Delta connection: In this type of connection, the end of one phase is connected to the beginning of the next phase, creating a closed loop between the phases.

The choice between these two schemes will depend on the type of load, the power required and the infrastructure available in the installation.

Connection to critical systems

In critical facilities such as hospitals, telecommunications centres or industrial plants, it is crucial that certain equipment is always kept operational. For this purpose, secure lines are implemented that directly connect critical systems to the generator set.

These lines are designed to receive power immediately in the event of a grid failure. In addition, many of these systems include redundancies and continuous monitoring, ensuring that the generator set is always ready to start when needed. In these cases, it is common to use several generators connected in parallel to improve security and supply capacity.
Doctors in a hospital reviewing an X-ray

Steps to connect a generator set safely

1. Assessment of the installation’s power and requirements

The first step to a proper connection is to make a detailed assessment of the power required by the installation during a power outage. This includes identifying the equipment requiring continuous supply and determining the rated and starting powers to be provided by the genset.

It is crucial to correctly calculate the critical load to ensure that the selected generator is able to cover all the needs of the facility without overloading.

2. Configuration of the Automatic Transfer Switchboard (ATS)

The ATS is responsible for the automatic switchover between the mains and the genset. Its correct configuration is key to ensuring that the system reacts quickly and efficiently to failures in the mains supply. This includes adjusting the delay times, the sensitivity of the system to detect fluctuations in voltage and frequency, as well as the generator start and stop settings.

A well-configured ATS not only ensures efficient switching, but also protects both the generator set and the connected equipment from possible fluctuations or failures in the grid.

3. Installation of conductors and protections

To ensure the safety of the installation, it is essential to correctly select the conductors and protective devices, such as fuses, differential and thermal relays. In three-phase installations, it is particularly important to ensure that the three phases are balanced to avoid problems of overload in one phase and underutilization in the others.

The dimensioning of the conductors must be done according to the capacity of the generating set and the distance between the generator and the switchboards. In addition, independent earthing systems must be installed to protect both personnel and equipment against possible insulation faults.

4. Connection and synchronisation tests

Once the installation is complete, it is crucial to perform extensive tests to ensure that the genset can transfer the load correctly without interruption. These tests include:

  • Verifying that the ATS responds appropriately to a simulated mains failure.
  • Checking that the genset can take the full load of the installation without sudden variations in frequency or voltage.
  • Perform synchronisation tests for installations where several generators operate in parallel, ensuring that all generators work in a balanced way and without interference.

In addition, the quality of the power supplied by the generator set should be verified, ensuring that it meets the requirements of the critical equipment of the installation.

A detailed analysis of the power requirements, the proper configuration of the automatic transfer switch (ATS) and the implementation of protective measures are essential to ensure a reliable and continuous power supply.

The key to success in these installations lies in designing a system that allows critical equipment to continue operating without interruption, ensuring the safety and efficiency of the entire electrical infrastructure.

Energy safety in the fight against climate change: risks and opportunities

Landscape with wind turbines at sunset, symbolizing the transition to renewable energy with energy safety and the fight against climate change.
For several years now, one of the biggest challenges in the fight against climate change has been related to the energy safety supply.

Although progress has been made, the energy sector is still the largest emitter of greenhouse gases and further efforts are needed. Also, energy production needs to be renewable and adaptable to already occurring climate conditions. Erratic weather patterns, rising global temperatures and the intensification of extreme weather events challenge the ability of energy systems to provide secure, continuous and affordable supply highlighting this need for adaptation.

Growth in energy demand

Climate change, combined with population growth and economic development, increases energy demand globally. E.g. The use of air conditioning systems in countries with emerging economies and warm climates, where income growth is allowing greater access to cooling technologies. In 2000, the global energy demand for residential air conditioning in summer was 300 TWh, but this is projected to increase to 4,000 TWh by 2050 in regions such as India, Brazil and other developing countries.

As global temperatures rise, these countries will experience longer and hotter summers, which will increase cooling use and thus electricity demand. Although in the more advanced economies and colder climates the need for heating during the winter is likely to decrease, overall energy demand will continue to increase due to the use of air conditioning in the summer months. This change in energy consumption patterns will require a reassessment of global energy strategies, with particular attention to the growing needs of developing countries.

Impact on power generation

Climate change is also affecting power generation. Thermal power plants, which currently produce around 80% of the world’s electricity, are reducing their efficiency due to higher ambient temperatures. Thermal conversion is less efficient in extremely hot conditions. In addition, the availability cooling of water is decreasing forcing them to operate at reduced capacities or even to temporarily halt power production. Thermal plants are designed to operate under more stable climatic conditions and, although most energy transition plans involve the closure of most of these, it must be kept in mind that this process will be gradual. During this transition period, thermal plants will remain a key part of the global energy supply, especially in countries where the infrastructure for renewable energy is not yet fully developed.

Nuclear power plants are particularly vulnerable to extreme weather events, such as hurricanes or storms, which can damage their cooling systems and other critical equipment necessary for the safe operation of reactors. Events such as Hurricane Harvey in 2017, which affected nuclear plants in Texas, highlight the need to strengthen energy infrastructures in the face of such events.

On the other hand, hydroelectric power, which depends on the hydrological cycle, is also at risk. In regions such as the Zambeze River in Africa, hydropower generation capacity is projected to decline by up to 35% by 2050 due to reduced rainfall and rising temperatures. However, in Asia, projections suggest an increase in hydropower capacity, showing that climate change will affect different regions differently.

In addition, renewable energies such as solar and wind are also exposed to the effects of climate change. Increased cloud cover in certain areas will affect the efficiency of solar panels, while more frequent and severe storms could damage both solar and wind installations. Extreme weather events and changes in wind patterns will complicate the integration of these sources into electricity systems, which may require greater investment in energy storage technologies to mitigate their intermittency.

Diagram of the energy system adaptation cycle in response to climate change.

Threats to energy infrastructure

Energy transmission and distribution infrastructures are particularly vulnerable to climate change. Higher temperatures, rising sea levels, melting permafrost, floods and landslides will put energy transmission networks and pipelines at risk. In coastal areas, rising sea levels may damage pipelines and energy facilities, while in permafrost areas, thawing could affect the stability of infrastructure. In addition, heat waves and forest fires that are becoming more frequent also pose a threat to power lines, as has already been seen in countries such as the United States and Australia.

The fossil fuel sector, in particular oil and gas, is also exposed to extreme weather events. Tropical cyclones, such as Hurricane Katrina in 2005, can disrupt operations on offshore extraction platforms and affect onshore infrastructure, leading to disruptions in global energy production and supply. Although the melting of ice in the Arctic presents an opportunity for exploration of new oil and gas reserves – which could increase the global supply of these resources – the exploitation of these reserves would entail new environmental and logistical risks.

The role of generating sets in energy safety

In this context of increasing energy demand and infrastructure vulnerability, gensets emerge as a vital solution to improve energy security. They act as back-up systems that ensure a continuous supply of electricity during outages or interruptions. Particularly useful for critical facilities, such as hospitals, data centres, wind farms and emergency services, which cannot afford interruptions in their power supply.

In addition, gensets are versatile and can be used in a variety of applications, from industrial operations to residential areas, providing an independent power source that can be tailored to the specific needs of each user. In regions where the electrical infrastructure is more vulnerable to disruptions, gensets can provide an effective emergency power solution, ensuring that communities and industries continue to function even during the most severe weather events.

Finally, the deployment of cleaner and more efficient gensets, powered by renewable fuels or clean energy technologies, can contribute to mitigating greenhouse gas emissions, aligning with long-term sustainability goals.

In this sense, gensets not only act as a temporary solution to energy supply insecurity but can also be integrated into a broader climate change adaptation and resilience strategy, offering both energy security and opportunities to move towards a more sustainable future.

What is it and how does the Mains/Genset switching work?

Power plant backlit against the sunset glow.
Mains/Genset switching is a key process in the installation of gensets, ensuring continuous power supply during grid failures. This mechanism is essential in critical sectors, where a lack of electricity can cause serious problems.

In this article, we explain in detail what Mains/Genset switching is, the different types of systems, and how to choose the most suitable for your installation.

What is a Mains/Genset switch?

Concept and definition

Mains/Genset switchover is the process of switching from the main power source (the mains) to a backup power source (the genset) when a mains failure is detected. This switching can be done manually or automatically and ensures continuity of power supply.

Importance in uninterruptible power supply

This process is essential in facilities that cannot afford a prolonged power outage, such as hospitals, industries or data centres. Thanks to switching, the generator set is activated to ensure that power continues to flow without interruption, avoiding economic losses and possible damage to sensitive equipment.
Imagen de industria con sistema de conmutación

Mains/Genset switchboards and diagrams

Mains/Genset switchboard: Function and components

The switchboard is an essential device in this process. It is composed of two power inputs: the mains and the generating set, and an output which distributes the electricity to the loads. While the grid is in operation, the switchboard keeps its input active, but in case of failure, it switches to the genset input.

Types of switching systems

Based on their operation, there are 3 types of switching systems:

  • Manual: Requires human intervention to switch from mains to genset.
  • Automatic: The system acts automatically as soon as it detects a mains failure.
  • Remote: Allows remote switching, which can be useful in decentralised installations.

Manual (local) switching

This is the simplest switching system. Manual switching requires an operator to physically intervene to switch from the mains to the genset. This type of system is usually used in installations where power outages do not have a serious impact or in cases where simplicity and low cost are a priority. The operator, in the event of a mains failure, must operate a switch or device to start the genset and transfer the load.

Advantages of Manual Switching

  • Reduced cost: Manual systems are more economical compared to automatic systems.
  • Simplicity: They are easy to install and operate in non-critical environments.
  • Direct control: The operator can decide when and how to switch.

Disadvantages of Manual Switching

  • Slow response time: Requires human intervention, which delays the reactivation of the supply.
  • Operator dependency: If no personnel are available, switching will not take place.
  • Risk of errors: Manual operation can lead to errors, such as failures in the switching procedure.

Automatic switching

Automatic switchover is the most advanced and efficient option. This system is designed to detect faults in the electrical network immediately and switch over to the generator set without human intervention. It is ideal for installations where continuity of power supply is crucial, as the process is fast and avoids prolonged outages.

Advantages of automatic switchover

  • Fast response: Switching is done in a matter of seconds, minimising outage time.
  • Increased reliability: No reliance on human intervention, reducing the margin of error.
  • Continuity of service: Ideal for critical installations where a prolonged outage could have serious consequences.

Remote switching

Remote switching allows remote switching between the grid and the genset to be performed remotely. This system is useful in decentralised installations or in large installations where physical access to the switching systems is not practical, such as telecommunications installations scattered throughout the territory.

The operator can activate the switching from a remote panel, a mobile device or via a programmed system.

Advantages of remote switching

  • Remote access: The system can be controlled from any location, which facilitates management in complex installations.
  • Operational flexibility: Can be integrated with other remote control and automation systems.
  • Reduced physical intervention: Reduces the need for physical travel to the equipment location.
  • Can be both automatic and manual (remotely).

Photograph of a city illuminated at sunset

Maintenance and considerations for Mains/Genset switching

Common problems and solutions in unstable networks

In areas with unstable power grids, switchboards can be damaged by constant power surges and outages. A common solution is to use surge arresters and opt for DC-supplied switchboards, which are less susceptible to mains fluctuations.

Maintenance of switchboards

Regular maintenance of switchboards is essential to ensure their proper functioning. It is recommended to check contactors and control relays, and to ensure that there is no wear or damage to coils or circuit breakers.

Mains/Genset switching is an essential component in any installation using generator sets as a backup power source. Selecting the right system and carrying out regular maintenance is key to ensuring that the power supply is continuous and uninterrupted.

Check this article for more information on connecting generators.

How much is a generator set worth: Key factors in calculating the price

Industrial generator being installed at a plant.

In the industrial sector, the choice of a genset is not only about finding the most economical equipment, but also about selecting the one that best fits the operational and strategic needs of the company.

Understanding which factors influence the price of a generator set is crucial to making an investment that guarantees reliability, efficiency and durability in the long term. We review them below.

Power

A critical factor that has a direct impact on cost. This value, expressed in kilowatts (kW) or kilovoltamperes (kVA), defines the load carrying capacity of the equipment. In an industrial environment, it is essential to select a generator set that not only meets current power demands, but also has room for future upgrades.

Higher power equipment is not only more expensive, but also requires a larger infrastructure for proper installation and operation.

Fuel type

Diesel generators, although more expensive than petrol generators, are preferred in industrial environments due to their durability, efficiency and lower maintenance costs.

On the other hand, gas gensets offer a more sustainable option with lower emissions, although their implementation requires the availability and cost of gas supply.

Technology and functionalities

The advanced features of a genset can significantly influence its price. Some aspects to consider include:

  • Automatic start-up: Ideal for ensuring operational continuity in the event of power outages.
  • Remote monitoring: Allows efficient and preventive management, reducing downtime and optimising maintenance.
  • Protection systems: Integration of systems to protect against overloads, short circuits and other operational risks.

Each of these features adds value to the equipment, but also increases its base cost.

Technician working on the installation of a new industrial generator.

Soundproofing options

The choice between an open-type or soundproofed genset will depend on its intended location. Soundproofed gensets are the choice in areas where noise control is a priority, such as hospitals or city centres, but are more expensive due to the additional sound insulation and materials required in their manufacture.

Applications and environment

The type of application for which the genset is intended also influences its price. Equipment designed for industrial use, capable of operating in extreme conditions or critical applications, is usually more robust and therefore more expensive.

When assessing the needs of a project, it is crucial to consider:

  • Environmental conditions: Equipment designed to operate in extreme climates, from sub-zero temperatures to desert conditions, will require specific modifications.
  • Regulations: Complying with emissions or noise regulations may require additional components that increase the price.

Industrial plant in a cold, snowy environment.

Summary of factors affecting the price of a generator set

  • Power: Directly proportional to the load capacity.
  • Fuel: Diesel, petrol or natural gas have different costs.
  • Technology: Automatic start, remote monitoring, or advanced protection. These are features that will increase the price.
  • Design: Open vs. Soundproofed. Soundproofing requires materials that come at an additional cost.
  • Application: Industrial, commercial, or extreme conditions.

By considering these factors, it is possible to choose the generator set that best fits the needs of each project, optimising the investment and ensuring reliable performance.

Genesal Energy is committed to offering tailored, high-quality solutions, backed by solid experience and specialised technical support.

How to calculate the generator you need

Technicians analyzing blueprints and details of an electrical project in an industrial setting.

Selecting the right genset is a critical task that goes beyond simply estimating power. An incorrect calculation can result in oversized equipment, which implies unnecessary costs, or undersized equipment, compromising the operation of the entire installation.

Below, we show you how to correctly calculate the generator set you need, considering all the technical factors involved.

How to proceed with power calculation

Firstly, you need to determine the required power, carrying out a load assessment. In order to do this correctly, it is also necessary to consider the start-up peaks caused by some types of loads such as electric motors.

Load assessment: The first step is to identify all the loads that the genset will have to feed. This includes machinery, electrical systems, safety equipment, and any other critical devices to be powered by the genset. It is essential to add up the constant powers of all these loads considering that all the loads might not be connected at the same time.

Consideration of start-up peaks: Some machinery has a peak electrical demand at start-up which can be between 2 and 5 times higher than their consumption in normal operation. Most commonly, these are the ones driven by electric motors, some examples and their classification are given below:

  • Light starting: Turbines and fans (2 to 3 times of normal consumption).
  • Medium start: Conveyor belts and compressors (3 to 4 times of normal consumption).
  • Heavy start-up: Cranes and lifting equipment (4 to 5 times of normal consumption).

Technicians working on the maintenance and inspection of a generator in an industrial plant.

Calculation will also depend on the type of motor drive. If the electric motor is powered by a frequency inverter (or other advanced system) the starting peak may vary. E.g. Direct starts, the most unfavourable case.

It is also important to know the moment each load shall be started as it may be the case that all the loads do not start at the same time, this is called the load-step start.

F.i. In order for the diesel engine to be able to handle the high starting peaks, a genset of twice as much power as the highest starting peak is considered.

Total power calculation: Sum of the constant powers identified in the load assessment.

Table for calculating the power of a generating set

The above calculations can be expressed in a table like this one:

Equipment / Load Constant Power (KW) Simultaneity factor Starting factor Start-up Power (kW) Load-Step Start Total Power (kW)
Machine A 5 1 3 15 1
Machine B 8 1 2 16 1
Lighting 3 1 1 3 2
Compressor 10 1 4 40 2
Fans 4 1 2 8 1
Total Constant Power 30 kW
Load-Step 1 Start-up 39 kW
Load-Step 2 Start-up 43 kW
Needed Power 86 kW (2 x 43kW)
Safety Margin (10%) 94.6 kW
Power Factor (0.8) 118.25 kVA

How to use this table

  • Equipment or load: List the equipment or loads to be connected to the genset.
  • Constant power (kW): Enter the rated power of each piece of equipment in kilowatts (kW).
  • Simultaneity factor: Indicate a figure to express how many loads are operating simultaneously.
  • Start-up factor: Apply a start-up factor for each equipment according to its type (e.g., 2 for light start-up, 4 for heavy start-up).
  • Starting power (kW): Multiply the power by the starting factor.
  • Starting step: Indicate the different steps to express which loads start simultaneously.
  • Total power (kW): Add the starting powers to obtain the total power required.
  • Safety margin: Apply a safety margin (10% in this case).
  • Power Factor: Divide the adjusted total power by the power factor (normally 0.8) to obtain the apparent power in kVA, which is used to select the genset.

Generator calculation formula

kVA = (Total Power in kW x Safety Margin) / Power Factor

The generator calculation formula allows technicians to accurately size a generator set based on real power demand and environmental conditions. The basic formula involves adding the constant load power (kW), considering start-up peaks, applying a safety margin (typically 10%), and dividing by the power factor (commonly 0.8) to convert kW to kVA. This ensures the selected genset can handle both steady loads and starting surges efficiently. Adjustments must also be made for altitude and temperature when applicable.

Snowy mountain landscape illustrating the challenges of operating generators in cold climates, where low temperatures can affect engine startup and efficiency.

Environmental conditions affecting genset power requirements

Extreme environmental conditions can have a significant impact on the performance and efficiency of a generator set. It is crucial to consider these variables when calculating the required power and selecting the right equipment.

Extreme temperatures

  • Low temperatures: In cold climates, engine start may be slower and engine oil may thicken, reducing efficiency and increasing wear. It is essential to consider a genset with engine & fuel preheating systems, as well as oil suitable for low temperatures.
  • High temperatures: Excessive heat can cause the engine to overheat and reduce the cooling capacity of the system. Generator sets in these environments should be equipped with enhanced cooling systems, such as larger capacity radiators or additional fans.

Altitude

At higher altitudes, air density decreases, which affects both combustion and cooling capacity. This results in a reduction of the power available from the genset. It is considered that for every 300 metres of altitude above sea level, engine power decreases by approximately 3-5%.

Adjustments required according to environmental conditions

  • Power adjustment: Recalculate the required genset power to consider losses associated with altitude and temperature.
  • Selection of suitable components: Ensure that the genset has specific components for operating in extreme environmental conditions, such as enhanced cooling systems or corrosion protection.
  • Additional maintenance and testing: Implement a regular maintenance programme that includes FATs in the actual environmental conditions in which the equipment will operate to ensure optimal performance and prevent unexpected failures.

Taking these environmental factors into account is essential to ensure that the genset will operate reliably and efficiently, regardless of the conditions it is exposed to.

Genesal Energy Engineering Department takes all these critical factors into account when designing and selecting the most suitable generator set for each project. We ensure that each piece of equipment is perfectly adapted to the specific environmental conditions and energy needs of our customers, guaranteeing optimum performance, durability and efficiency, no matter where.