Manufacturing Customer Stories
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Reliable Interim Power Solution
Finding reliable and cost-effective interim power solution in a developing area with an equally developing grid was the challenge. The solution – a Cat genset providing prime power for the whole facility, with a planned conversion to standby use when the power grid stabilizes.
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Conduspar reduces electrical costs by 35 percent with peak shaving
Company officials determined they could reduce electrical costs by producing their own power during evening hours rather than relying on the utility companies. In 2009, Conduspar installed a Cat® 3412 diesel generator set devoted to standby power for a copper oven used in the process of melting and extruding copper into wire. Later, the company added two Cat C32 ACERT™ diesel generator sets to supply standby power for overall factory operations. These three generator sets also allow Conduspar to engage in peak shaving activities during evening hours when power is most expensive.
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North Church Gravel expansion plans include reliable rental power
North Church Gravel turned to Caterpillar for temporary power to launch the expansion of the company’s 365-acre site in northern New Jersey. Working with Cat® Dealer Foley Power Systems, the operators of North Church Gravel selected the Cat XQ800 mobile diesel generator set for reliable rental power.
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Harnessing lost energy from machine testing process
The Endurance Facility started as a concrete pad with a basic enclosure for a pre-production C175-16 3MW diesel generator set. In 2011, it grew to include a then pre-production G3520E generator set and then - prototype G3516H genset - both powered by natural gas. The facility also includes a pre-engineered structure that houses the entire electrical and mechanical infrastructure required to tie the gensets into LEC’s electric utility feed.
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"Black start" diesel generator provides stand-alone capability
Kyocera uses the waste heat from its cogeneration facility to feed the chillers that air condition the plant. Beyond power consumption considerations, the plant requires low humidity and an optimum furnace temperature range for the manufacture of its ceramic packages and other sensitive products. Originally, Tanaka investigated the possibility of using turbines for cogeneration; however, diesel generators proved to be a better match for Kyocera's chilled water needs.
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Scalable power solution works with recovered biogas
GZBC has completed testing of the Cat generator sets and is in the process of completing their phased integration into the power supply of the brewery. Caterpillar and CEL were able to design the CCHP system and its installation to meet the customer's unique demands. The new generator sets make use of the plant's recovered biogas to generate power and would transfer waste heat into a cooling source.
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Generator waste heat increases efficiency from 35 to 70 percent
Plainville Electrical Products Company (PEPCO) has been designing and manufacturing electrical control systems and distribution panels for commercial and shipboard use since 1922. Many of these systems have been installed on U.S. Navy ships and large yachts. PEPCO has also designed a number of power management and generator control systems for utility applications. With experience in the utility market and extensive knowledge of control systems design, the PEPCO engineering team combined these areas of expertise to create a cogeneration plant that would be ideal for manufacturing and commercial facilities, including hotels, hospitals, data centers and other facilities with large heat loads. The waste heat from the generator powers two absorption chillers. These combination chiller/heater units provide 95 percent of the facility’s heating and cooling needs. By harnessing this waste heat, the system efficiency is increased from 35 percent to about 70 percent.
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The power to drive fuel costs down, performance up
Mexico’s largest integrated steelmaking company produces 5 million metric tons of liquid steel annually for hot- and cold-rolled coil. Their challenge was met through Cat CG260-16 gas powered engines.
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Flexible power and diversified strategy nets profits
With the rise of the Internet, demand for newsprint has decreased and many mills have closed down. See how an onsite power plant using Cat® G16CM34 generator set power helps one paper mill continue to thrive in a declining industry.
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Dependable power for delicate freeze-drying processes
With the largest and most modern freeze-drying capabilities in Brazil, Liotécnica depends on a consistent flow of power to maintain its perfected freeze-drying methods. With attractive equipment financing options available from Cat® Financial, the company decided to purchase two diesel generator sets for reliable standby power and peak load shaving.
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Biogas-fueled Cat® generator powers factory
The Kalasin Starch factory uses the fruit of the tapioca plant to produce starch for food and medical products. The organic waste generated from the starch production process is channeled to an anaerobic digester, where it generates methane gas that will be used to fuel the Caterpillar gas generator. Approximately 12,000 Nm3 of digester gas is generated daily and will be fed to the gas generator for power generation. The power generated from the biogas-fueled generator will be sufficient to meet the entire power requirement of the plant.
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