Diesel generator sets (gensets) provide critical backup and prime power for hospitals, data centers, telecom towers, industrial facilities, and remote locations. Regulations: EPA Tier 4 Final, EU Stage V, China Stage IV. Unlike mobile equipment, gensets operate at steady-state speeds (1,500 or 1,800 rpm), enabling optimized aftertreatment. We provide validated DOC, DPF, and SCR systems for standby and prime-power gensets from 50 kW to 3+ MW.
Gensets operate under three duty cycles:
Each requires tailored aftertreatment. Standby gensets need catalysts that survive years of idle and reach light-off instantly.
Genset Type | Power Range | Aftertreatment Configuration |
Standby / emergency | 50–500 kW | DOC → DPF (SCR optional) |
Prime power / continuous duty | 100 kW–3+ MW | DOC → DPF → SCR → ASC → Tailpipe |
Retrofit / pre-regulation | 50–500 kW | DOC → Tailpipe |
Converts CO and HC, generates NO₂ for passive DPF regeneration. Oversized for high exhaust flow and steady-state operation. Poison-resistant for variable diesel fuel. Durable for long idle periods.
Traps soot and ash. Predictable passive regeneration (250–350°C). Active regen rarely needed. Ash cleaning: 5,000–10,000 hrs (prime power), 10+ years (standby). Cordierite or SiC wall-flow substrate.
Primary NOx removal for prime/high-power gensets. Vanadia-based (V₂O₅/WO₃/TiO₂) for sulfur tolerance. Cu-zeolite for low-temp/ultra-low NOx. Conversion efficiency: 90–95%.
Reduces NH₃ slip to <10 ppm in enclosed environments (hospitals, data centers). Pt on alumina.
Pollutant | Engine Out | After Aftertreatment (Tier 4 Final / Stage V) | Efficiency |
NOx | 300–1,000+ ppm | <0.67 g/kWh (Prime) / <4.0 g/kWh (Standby) | 85–95% |
PM | 0.1–0.5 g/kWh | <0.03 g/kWh | >90–95% |
CO | 100–500 ppm | <10 ppm | >95% |
HC | 50–200 ppm | <10 ppm | >95% |
Genset Type | Power Range | Duty Cycle | Aftertreatment | Key Requirements |
Standby (emergency backup) | 50–500 kW | <50 hrs/year | DOC + DPF | Long idle, instant start |
Standby (data center, hospital) | 500 kW–2 MW | <100 hrs/year | DOC + DPF + SCR | Ultra-reliable, NH₃ slip control |
Prime power (remote mine, island) | 100 kW–1 MW | 1,000–3,000+ hrs/year | DOC + DPF + SCR + ASC | Durability 20,000+ hrs, fuel efficiency |
Continuous (grid stabilization) | 1–3+ MW | 5,000–8,000 hrs/year | DOC + DPF + SCR + ASC | High load factor, low operating cost |
Oil & gas (wellhead, pipeline) | 50–500 kW | 500–2,000 hrs/year | DOC + DPF | Explosion-proof, hazardous location |
Marine auxiliary | 100 kW–1 MW | 1,000–5,000 hrs/year | DOC + DPF + SCR + ASC | Corrosion resistance, space constraint |
Corrosion-resistant internals, electric pre-heaters (<60 s light-off), automatic self-checks, no DEF tank heaters required.
Vanadia SCR for sulfur tolerance, oversized catalyst (2–3× on-road) for 20,000+ hrs, serviceable canning.
SCR efficient 30–100% load, DEF dosing modulated by exhaust temp and NOx sensors, thermal management ensures 250°C+.
Low-ΔP DPF (2–4 kPa), high-porosity substrates (>60%), straight-through exhaust. Engine power loss <1% at rated load.
Fits within genset enclosures, high-temp routing, spark arrestors, low surface temperature (<180°C).
Reports DPF soot load, SCR efficiency, DEF level, catalyst temps, fault codes. Predictive maintenance and load-bank testing.
Hundreds of genset systems worldwide. Validated to EPA Tier 4 Final, EU Stage V, China Stage IV.
Electric pre-heaters, self-check cycles, corrosion-resistant designs.
Vanadia SCR, oversized catalyst volume, serviceable design for low total cost of ownership.
Remote monitoring, predictive maintenance alerts via cellular or satellite.
From 100 kW standby gensets to 3 MW prime-power systems, our aftertreatment solutions deliver compliance, reliability, and low total cost of ownership. Partner with us to engineer your path to cleaner power generation.