Case Studies / Genset & Power
Genset Exhaust Retrofit in Jiangmen, Guangdong
Dual DOC plus 24 metal filter cores: black smoke and CO treated in one unit
1. Project overview
| Location | Jiangmen, Guangdong Province, China (client name withheld on request) |
|---|---|
| Generator | Mitsubishi Heavy Industries MGS1500B diesel generator set |
| Rated output | 1800 kVA / 1440 kW |
| Speed / frequency | 1500 rpm, 50 Hz |
| Voltage / current | 380 V / 2735 A |
| Duty | PRIME, continuous load |
| Condition before retrofit | Visible black smoke plus CO and odorous gases; poor workshop air quality; not compliant with local emission requirements |
2. Three constraints that could not be avoided
- Black smoke. Under high load the set smoked heavily. Visible smoke is the first thing an inspector or a neighbour notices.
- CO and gaseous pollutants. Carbon monoxide is colourless, toxic and irritating. A plain particulate filter captures soot but leaves CO untouched.
- Power supply must not be compromised. The set carries production load. Excessive backpressure means derating or a shutdown, and that loss outweighs the pollution problem.
The plant had been running a water-filter type purifier. It wetted and settled part of the dust, did nothing for CO, and brought secondary problems: wastewater, winter freeze-up and heavy maintenance.
3. The solution: one unit, three stages
The TKPD-24 integrates three functions in a single casing:
- Two parallel DOCs oxidise CO and HC into CO2 and water and reduce the odorous fraction.
- 24 metal filter cores (metal DPF) capture soot. They tolerate heat and vibration and can be cleaned and regenerated instead of replaced.
- Emergency bypass valve opens when backpressure reaches the set point, so the set keeps supplying power under any condition.
In short: the parallel DOCs handle the gas, the metal cores handle the smoke, and the bypass protects the power.
4. Specifications and installation
| Model | TKPD-24 combined purifier |
|---|---|
| Application | Diesel genset exhaust (PM + CO / HC) |
| Filter stage | 24 metal filter cores (metal DPF) |
| Catalyst stage | Two DOCs in parallel |
| Inlet / outlet diameter | 325 mm |
| Overall dimensions (L×W×H) | Approx. 2610 × 1547 × 1982 mm |
| Safety features | Emergency bypass valve and control box |
| Stack outlet | Rain-cap outlet |
The unit flanges onto the genset exhaust. Exhaust is split across the two parallel DOCs, recombines before the metal cores, and leaves through the rain cap; the control box tracks backpressure and opens the bypass at the set point.
5. What changed on site
- No visible smoke. The 24 metal cores capture the particulates; at this installation the stack showed no black smoke to the eye.
- Gaseous pollutants treated. The two parallel DOCs oxidise CO and HC; the workshop odour was noticeably reduced.
- Power continuity intact. The emergency bypass stayed in the loop and the set ran normally after the retrofit.
- Lower exposure for staff. Air quality in the workshop improved and operators no longer work in smoke and CO.
One caveat: compliance depends on the local limit, the test cycle and fuel quality, and is confirmed by an accredited laboratory on site. This page documents the equipment installed and what was observed at this project.
6. Where it applies
The TKPD series suits high-power diesel gensets that need both smoke and CO control while power continuity is critical: factory captive and standby sets, data centre backup, hospital emergency generators, commercial complexes and hotels, telecom sites and temporary event power.
7. FAQ
How do metal filter cores compare with ceramic DPFs?
Metal cores tolerate high temperature and vibration, which suits gensets with frequent starts and load swings, and they are cleaned and regenerated rather than replaced, keeping long-term maintenance costs down.
Why two DOCs instead of one?
Genset exhaust flow is high, so a single DOC within the same footprint has limited oxidation capacity. The TKPD-24 arranges two DOCs in parallel: exhaust is split between the two catalyst cartridges, doubling the catalyst volume without enlarging the unit. That provides enough capacity for CO and HC, reduces odour, and keeps backpressure low.
Does the emergency bypass cause excess emissions?
The bypass is a protection mechanism for extreme conditions only, so power is never interrupted. Once routine core cleaning restores backpressure, the valve closes automatically and all exhaust returns to the purification path.
Is maintenance burdensome?
No. Metal cores are cleaned and regenerated instead of replaced, and the control box monitors backpressure with maintenance prompts. Daily upkeep is minimal.
8. Related products and cases
- TKPD multi-core metal filter dry purifier — the model used here.
- Metal filter bags and cartridges — media, construction and regeneration.
- DOC + SCR + DPF + ASC purifier — when NOx also has to be controlled.
- Case studies — more field installations.
A similar genset to treat? Send us the model, rated power, exhaust outlet diameter and available room space. We will run a sizing check first, then decide whether a site survey is needed.
Bruce Wen · +86 188 1936 6808 (mobile / WhatsApp / WeChat) · bruce.wen@aifiltech.com