Captive Power Co-generation Plants

Enerzone Engineering Services (EES) offers comprehensive consultancy solutions for the planning, design, and implementation of gas genset-based captive power co- generation plants, enabling industries to achieve energy independence, operational reliability, and cost efficiency. Our services are tailored to meet the growing demand for sustainable and efficient power generation solutions that simultaneously address both electrical and thermal energy needs.

Our team of experienced engineers and energy consultants provides complete Project Planning, Design & Engineering support for establishing new co-generation facilities or upgrading existing powerhouses. This includes feasibility studies, load profile analyses, selection and sizing of gas gensets, and system integration with existing utility networks and process loads.

EES specializes in the design of Waste Heat Recovery Systems (WHRS) utilizing exhaust gases and jacket water heat for steam or hot water generation, enabling clients to maximize overall system efficiency and significantly reduce fuel consumption.

Integration Studies for connecting co-generation systems with existing process utilities and renewable sources such as Solar PV systems.

EES conducts Comprehensive Energy Audits to evaluate the performance of existing co-generation systems. Through a detailed analysis of fuel utilization, electrical output, thermal recovery, and system losses; our experts identify inefficiencies and recommend actionable measures for improving both electrical and thermal efficiency. These audits also include cost-benefit analyses and emission reduction assessments, providing clients with a clear roadmap toward enhanced productivity and sustainability.

Scope of Services

  1. Project Planning, Design & Engineering for setting up of new Gas Genset-based captive power co-generation plants or revamping, up-gradation & modernization of existing powerhouses.
  2. Design & Engineering of Waste Heat Recovery Systems utilizing Jacket water heat and Exhaust gases for generation of Hot water and/ or Steam to operate WHRB or Absorption Chiller.
  3. Review and Development of Single Line Diagrams (SLD) for existing electrical systems to ensure proper load distribution and system integrity.
  4. Data Analysis of Utility (Grid) Supply Bills to evaluate Maximum Demand Indicator (MDI), consumption trends, and load management opportunities.
  5. Assessment of Solar Energy Generation Data for integrating renewable energy into the co-generation system.
  6. Comprehensive Load Profile Studies covering peak, average, and base load demands to optimize Genset operation and energy utilization.
  7. Selection and Sizing of Gas Gensets based on load requirements, fuel availability, and efficiency considerations.
  8. Feasibility Studies for Gas-Fired Gensets including technical, operational, and economic evaluations.
  9. Powerhouse Layout Planning ensuring safety, accessibility, and efficient equipment arrangement.
  10. Preparation of Bill of Quantities (BOQ) for electrical and mechanical works covering complete installation and commissioning scope.
  11. Integration Studies for connecting co-generation systems with existing process utilities and renewable sources such as Solar PV systems.
  12. Comprehensive Energy Audits for existing Co-generation systems to assess electrical and thermal efficiencies; identify losses and recommend performance optimization measures.