Tag Archive for: Genesal Energy

Backup power to preserve marine life: we designed a generator set for a fish farm prepared for a marine environment

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Genesal Energy has developed a tailor-made power solution for a fish farm located in the Atlantic Coast of Northwest Spain, an area especially exposed to corrosion issues.

The project involved the design and manufacture of a 440 kVA genset operating in parallel with two existing generators, ensuring production continuity even in the event of grid failures or instability.

Fish farms require a constant and reliable power supply to run essential systems such as water pumps, aerators, recirculators and sensors. A power outage can reduce oxygen levels in the water and suffocate the fish within hours, with severe economic and environmental consequences.

A highly demanding environment

The coastal location posed an additional challenge in terms of resistance and durability. Genesal Energy engineering department designed an open generator protected by an ISO12944-C5 anti-corrosion coating, ideal for harsh marine environments. The alternator was also marinised and fitted with anti-condensation heaters, increasing its resistance to humidity and salinity.

The solution includes an integrated 350-litre fuel tank providing up to 4 hours of autonomy, and a rubber anti-vibration system to protect the structure against mechanical vibrations.

Synchronisation and full control

The key to the project was to ensure seamless operation alongside the two existing units. To achieve this, a ComAp InteliLite AMF 25 IL4 control panel was integrated, enabling the load distribution management and remote control of the installation. Specific safety features such as emergency stop buttons and guards for hot and moving parts were also added, meeting the required safety standards.

Thanks to this bespoke design, the fish farm now benefits from a robust, efficient backup system ready to operate under extreme weather and environmental conditions, ensuring not only production continuity but also the survival of thousands of fish in the event of an energy emergency.

Features

  • 440 kVA (Standby) / 400 kVA (Prime) genset.
  • Operation alongside two existing generators.
  • Integrated 350 L tank (4 hours’ autonomy).
  • ISO12944-C5 anti-corrosion paint treatment.
  • Marinised Mecc Alte alternator with anti-condensation heaters.
  • ComAp InteliLite AMF 25 IL4 control panel.
  • Legrand 630 A circuit breaker.
  • Tudor TC1453 2x 145 Ah batteries.
  • SE 45 silencer model (-28 dB).

Energy security in emergencies at one of the UK’s main airports: designing a generator with acoustic insulation and fire protection

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Genesal Energy has designed a bespoke power solution for Manchester Airport, one of the busiest in the United Kingdom, with the aim of strengthening its backup system in the event of grid failures.

The project involved the design and manufacture of a fully customised 770 kVA generator set, integrated into a 20ft container and adapted to the client’s requirements in terms of dimensions, acoustic insulation and fire protection.

In critical infrastructures such as airports, where any interruption can cause significant operational issues, having a reliable auxiliary power system is essential. These units must guarantee uninterrupted operation of facilities, especially in strategic areas such as lighting, communications, security and signalling systems.

Adapted to a highly demanding environment

One of the main challenges of the project was fitting the generator into a reduced-size room without sacrificing the power needed to supply the airport’s critical loads. To achieve this, the genset was integrated into a compact 20ft DV container with a reinforced external design and two adjoining modules: one for sound attenuation and the other for fire protection, complying with EI60 classification.

In addition, motorised louvres were installed at the air inlet and outlet, together with fire dampers, automatic fuel shut-off valves and other measures to guarantee compliance with safety standards and airport regulations.

Grupo electrógeno móvil para eventos con diseño ligero.

Maximum autonomy and silent operation

The generator, powered by a Volvo engine with 700 kVA Prime output, is designed to operate continuously at full load for at least 6 hours, thanks to a 1,700-litre fuel tank. Acoustically, it was designed as an oversized MD 250 model (-40 dB), enabling it to operate below 75 dB(A) even under full load, minimising any noise interference within the airport environment.

In critical infrastructures such as airports, where any interruption can cause significant operational issues, having a reliable auxiliary power system is essential.

The solution also includes an oil heater with thermostat, a double breaker in the power panel for both the genset and the load bank, and exterior LED luminaires (IP69K), ready for extreme conditions.

This development is an example of how customised engineering allows the design of reliable, safe power systems adapted to environments with the highest technical and operational requirements, such as international airports.

Features

  • 770 kVA (Standby) / 700 kVA (Prime) generator set.
  • Installed at Manchester Airport (United Kingdom).
  • Integrated into a 20’’ DV container adapted to limited space.
  • EI60 fire protection: fire dampers and automatic valves.
  • Oversized sound attenuation module.
  • Noise level below 75 dB(A).
  • Large-capacity fuel tank (1,700 L).
  • Deep Sea DSE8610 control panel.
  • Motorised air inlet and outlet louvres.
  • Double breaker in power panel (genset + load bank).
  • LED exterior luminaires (IP69K).
  • Oil heater with thermostat.
Genesal Energy supplies five generator sets to water pumping stations in Lithuania

Genesal Energy supplies five generator sets to water pumping stations in Lithuania

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Genesal Energy works every day to deliver power solutions that protect what matters most. And few things are more essential to life than access to clean drinking water.

That’s why we’re proud to have contributed to safeguarding this vital resource at water treatment plants in Lithuania, where we supplied five generator sets specifically designed to ensure continuous operation of the facility in the event of a power failure.

The plants play a key role in the daily water supply and in the treatment of wastewater. It required a reliable backup power system capable of activating instantly in the event of a grid outage, as any disruption could compromise critical processes such as pumping, purification, or waste control. In real terms, this could lead to homes without water, health risks, or serious environmental impacts.

The Genesal Energy engineering team designed the generator sets to activate immediately in the event of a power failure.

Our engineering team designed a solution made up of five generator sets: two 110 kVA units and three 275 kVA units, all installed in soundproof enclosures and equipped with high-capacity fuel tanks made of stainless steel – a material especially resistant to humidity and corrosion. Key design features included a flexible coupling system between the engine and alternator, a low-noise configuration (-30 dB), and 500W and 1,000W engine heaters to enable efficient cold starts.

Additional features included digital oil level sensors and a special RAL 5012 paint finish, customised to the client’s specifications.

Blue Genesal Energy generator built for a water treatment plant in Lithuania

The Engineering Solution

The Genesal Energy engineering team designed the generator sets to activate immediately in the event of a power failure. This rapid response capability prevents key processes such as water distribution or waste treatment from stopping.

Main Features

  • Design: Monoblock engine-alternator in 2,900 and 3,400B soundproof canopies
  • Calculated exhaust inlet/outlet section dimensions for installation
  • Integrated base frame tanks with 400L and 500L capacity
  • Flexible coupling system between engine and generator
  • Oversized low-noise model (-30 dB)
  • Engine heaters of 500W and 1,000W
  • Circuit breakers of 160 A and 400 A
  • Digital oil level sensors (high and low)
  • Customised paint finish – RAL 5012
Generator for the industrial sector

Uninterrupted production thanks to Genesal Energy in the industrial sector

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Genesal Energy has developed a new project for a company in the industrial sector in the UK, guaranteeing a constant power supply in a plant where operational continuity is key to profitability.

The generator was supplied, installed and commissioned through Ingram Installations Ltd., ensuring the equipment was ready to operate under the highest reliability standards.
When production cannot stop, power must respond. Any disruption to the power supply can result in loss of production, material damage and even contractual penalties. That is why having a robust and secure back-up system is a strategic need.
Genesal Energy generator installed outdoors at an industrial facility in the UK

Our Engineering solution

Our engineering department designed a soundproofed generator set, mounted on a steel frame with direct coupling between engine and alternator. The system includes an integrated 950 litre tank with a liquid collection tray, providing an autonomy of up to 8 hours of continuous operation.

An external linkbox was installed in a closed cabinet, facilitating the connection of power and control cables in complete safety for the operators.

To optimise performance and durability, anti-condensation heaters were incorporated into the alternator, an anti-vibration system with rubber mounts, and protective mesh in the openings to prevent the entry of animals.

Genesal Energy generator installed outdoors at an industrial facility in the UK
In addition, an external linkbox was installed in a closed cabinet, facilitating the connection of power and control cables in complete safety for the operators. The generator also includes all the required protection systems: emergency stop mushrooms, protections for moving parts and hot elements, always guaranteeing safe operation.

Features

  • Construction: 5000 Canopy
  • Tank: 950L integrated in baseframe
  • Silencer model: GSA 650 (-30dB)
  • Deep Sea DSE7310 MKII control panel
  • Installation of anti-condensation resistors in the alternator
  • External connection linkbox
Generator supplied by Genesal Energy for RCD Espanyol’s training ground

Genesal Energy reinforces stadium power supply with a 400 kVA genset at RCD Espanyol

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RCD Espanyol has entrusted Genesal Energy to reinforce its electricity supply by installing a 400 kVA generator set in his Barcelona Stadium. Designed to guarantee energy continuity in the event of a grid failure during the broadcasting of the women’s team’s matches in these facilities.

In this type of infrastructure any interruption can have economic, logistical and reputational consequences. It is therefore essential to have back-up systems that ensure the operation of the facilities and the safety of the attendees.

To ensure long autonomy, the set is fitted with a 700 litres tank integrated in the base frame.

In this type of infrastructure any interruption can have economic, logistical and reputational consequences. It is therefore essential to have back-up systems that ensure the operation of the facilities and the safety of the attendees.
In professional football, the requirements are even higher. Organisations such as UEFA and FIFA establish strict regulations that require redundant energy solutions, capable of coming into operation immediately. RCD Espanyol’s trust in Genesal Energy demonstrates our experience in the development of advanced energy solutions for spaces with intensive use. Thanks to our customised design capacity, we are able to adapt to the highest technical and regulatory standards.

Our Engineering solution

Our engineering team designed a 400 kVA prime power generating set, mounted in a 3,900 mm soundproof canopy, specially adapted for urban environments and noise-sensitive areas.

To ensure long autonomy, the set is fitted with a 700 litres tank integrated in the base frame. The system also includes a double set of Tudor TC1453 batteries (145 Ah) connected in parallel, which ensures that the equipment will start even in the event of a battery failure.

In terms of safety, the generator has a 630 A circuit breaker to protect the installation against overloads and short circuits. A 1000W Hotstart preheating system was also incorporated, which keeps the engine in optimum condition for immediate start-up.

Features

  • Type of construction: Monoblock engine-alternator in soundproofed canopy.
  • 700 litres fuel tank in base frame.
  • Silencer model: GSI 490 (-30dB).
  • 2 x Tudor TC1453 145 Ah batteries.
  • ComAp InteliLite AMF25 IL4 control panel.
  • 630 A Circuit Breaker.
  • Hotstart 1000W preheating system.

We designed an emergency solution that meets the highest environmental standards in Europe. See our latest Engineering feat in Belgium

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Genesal Energy has successfully completed a project to guarantee emergency power supply for a combined cycle power plant — a critical infrastructure in the heart of Belgium.

These types of facilities must be equipped with emergency generators, as any brief power outage can compromise safety systems such as water cooling, fire suppression, lighting, and auxiliary systems that are essential for the plant’s proper operation.

To prevent the risks associated with grid failure, two soundproofed generator sets were designed in 40ft containers for medium-voltage generation, connected in parallel to each other and the grid. A third 20ft container serves as a high-tech electrical room housing the central control system and medium-voltage switchgear. The installation also includes auxiliary systems for heating, air conditioning, and exhaust gas post-treatment, along with specific thermal insulation to improve overall plant efficiency.

The combined cycle plant in Belgium now has a robust, efficient and environmentally friendly emergency power system.

Safety was paramount in the project. Fuel tank heaters with ATEX (Explosive Atmospheres) certification were installed to prevent any risk of explosion and to withstand extremely low temperatures. Additionally, the containers were fitted with liquid collection trays and leak detectors that activate immediately in case of a spill, effectively preventing environmental contamination.

The electrical system was designed for remote management. The electrical room container includes an advanced control panel that enables simultaneous operation of both generator sets. Medium-voltage grounding resistors, automatic circuit breaker cells and a common power output system were also installed, allowing either generator to be isolated as needed.

Meeting strict environmental standards

One of the biggest challenges of the project was meeting Belgium’s environmental regulations – among the strictest in Europe. Our engineering team developed an integrated solution that includes an advanced exhaust gas post-treatment system with DPF filters, SCR technology, and a mixing chamber for urea injection, guaranteeing ultra-low emissions and full compliance with the most demanding standards.

Continuing with this focus on sustainability, components were also installed to reduce the noise level to below 80 dB at 1 m. Motorised air louvers were also included to isolate the equipment from ambient conditions during periods of inactivity.

Strategic collaboration with Mitsubishi

Mitsubishi’s collaboration was key to ensuring the reliability and performance demanded by a project of this scale.

Mitsubishi’s team worked closely with Genesal Energy’s engineering departments throughout the design process, ensuring seamless technology integration. This cooperation was essential to achieve optimal performance in critical conditions while meeting the project’s demanding environmental and operational requirements — in line with Europe’s strictest standards for emissions, efficiency, and sustainability.

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Commitment to tailored engineering

The project developed in Belgium is a clear example of Genesal Energy’s commitment to tailor-made engineering, sustainability and energy efficiency applied to critical infrastructures. From design to commissioning, every decision was aimed at ensuring maximum operational reliability, environmental responsibility and compliance with the most demanding European standards.

Beyond its technical complexity, this installation reflects a vision of energy based on innovation, collaboration and excellence. Genesal Energy has proven its ability to tailor every component, optimise every system, and rely on strategic partners like Mitsubishi to successfully deliver a robust, safe and reliable emergency solution.

Features

  • Two 4,400 kVA emergency generators operating in parallel and connected to the grid in Belgium.
  • Two 40 ft containers and one 20 ft container acting as an electrical room with medium-voltage switchgear and advanced remote control.
  • Remote and automated management through a next-generation Master Panel.
  • Exhaust gas post-treatment system.
  • ATEX-certified fuel heaters for optimal performance in cold climates.
  • Integrated diesel and urea tanks.
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.