Aug 29,2023
In today’s world where uninterrupted power supply is critical to every industry, business and even home, generators play a vital role. Among the many types of generators, natural gas generators are popular for their efficiency, cleanliness and reliability.
In this blog post, we’ll delve into the intricacies of how natural gas generators work, exploring their components, features, benefits, and factors to consider when determining the proper size for different applications.
We maintain a large inventory of high-quality natural gas generators ready for fast delivery across a wide range of applications. From generator selection and system design to installation and after-sales support, our team provides complete power solutions tailored to your project requirements.
A natural gas generator produces electricity by using natural gas as its primary fuel source. Compared with traditional diesel-powered systems, natural gas generators offer lower fuel costs, cleaner emissions, and quieter operation, making them a popular choice for commercial, industrial, and utility applications.
Natural gas is one of the most widely used fuels for power generation in the United States. Thanks to its availability, efficiency, and environmental advantages, natural gas continues to play a major role in supporting reliable power generation across the country.
Whether you need backup power for a critical facility or a continuous power solution for industrial operations, our natural gas generator systems can be customized to meet your specific power requirements.
A natural gas generator consists of multiple precision-engineered components that work together seamlessly to produce reliable electrical power for your business’s essential equipment and daily operations. Below are the key parts that make up a natural gas generator:
Fuel: The first requirement for operating a natural gas generator is a reliable fuel source. In most cases, the generator can be connected directly to an existing municipal natural gas pipeline, providing a continuous and dependable fuel supply. This direct connection eliminates the need for on-site fuel storage and helps reduce the risk of operational interruptions caused by fuel shortages.
Combustion Chamber: At the heart of the engine is the combustion chamber, a sealed space where the air and natural gas mixture is compressed and ignited. The combustion process releases energy that powers the engine and initiates electricity generation.
Piston: The piston moves continuously up and down inside the combustion chamber. Its motion compresses the air-fuel mixture before ignition, allowing for more efficient combustion and improved engine performance.
Spark Plug: The spark plug is a compact but essential component that extends into the combustion chamber. It generates the electrical spark needed to ignite the compressed air-fuel mixture, triggering the combustion process.
Crankshaft: Connected directly to the piston, the crankshaft converts the piston’s reciprocating motion into rotational energy. This rotating force drives the generator’s rotor, which is responsible for producing electrical power.
Stator: The stator is the stationary part of the generator, consisting of multiple insulated copper windings arranged around the rotor. It creates the magnetic field necessary for electricity generation.
Rotor: The rotor is the rotating electromagnetic component located inside the stator. As it spins, it interacts with the stator’s magnetic field to generate a stable and continuous flow of electrical current.
The operation of natural gas generators can be divided into several key steps:
Intake: The engine draws in ambient air through the intake system.
Compression: Air is compressed within the engine cylinders, increasing its pressure and temperature. Compression is a critical step in the combustion process as it prepares the air for the introduction of fuel.
Fuel Injection: Natural gas is injected into the combustion chamber in a controlled manner. This gas is mixed with compressed air.
Lgnition: The spark plug ignites the air-fuel mixture. The burning mixture expands rapidly, producing high-pressure gases.
Power stroke: The expansion of the gas forces the piston inside the cylinder to move. This motion translates into rotational motion, which drives the engine’s crankshaft.
Power generation: As the engine’s crankshaft spins, it turns the alternator’s rotor, creating a rotating magnetic field. This magnetic field induces a current in the stator coils, which generates electricity.
Exhaust: After the power stroke, exhaust gases exit the combustion chamber through the exhaust system.
Cooling and Lubrication: Throughout the process, the engine’s cooling system ensures that temperatures remain within safe limits. The lubrication system also ensures the smooth operation of moving parts.
Natural gas generators are generally classified into two main categories: **standby generators** and **prime generators**. Each type is designed for different operating conditions and power requirements.
Standby generators are the most common type of natural gas generator used in residential, commercial, and industrial applications. These systems are permanently installed and connected directly to the local natural gas supply.
When a utility power outage occurs, the generator automatically starts and supplies backup power to critical equipment and systems. Once utility power is restored, the generator shuts down and returns to standby mode.
Because standby generators are intended for emergency backup power only, they are not designed to operate continuously for extended periods. Prolonged operation can increase wear on components and may lead to more frequent maintenance requirements.
One of the key advantages of a natural gas standby generator is its virtually unlimited fuel supply. Since natural gas is delivered through underground pipelines, fuel is continuously available without the need for on-site storage tanks or refueling. Unlike diesel fuel, natural gas does not degrade over time, making it a reliable long-term backup power solution.
Prime generators are designed to serve as the primary source of electricity when utility power is unavailable or inaccessible. In these applications, the generator supplies all of the power required by the facility.
Prime power systems are commonly used at construction sites, remote industrial facilities, oil and gas operations, mining projects, and other locations where grid power is limited or unavailable.
Unlike standby generators, prime generators are built to operate for extended periods and handle varying electrical loads throughout the day. They feature more robust designs and higher-duty components to support continuous operation under demanding conditions.
Continuous power generators are a specialized type of prime generator. While both are designed for long operating hours, continuous power generators are engineered to run at a constant load for an unlimited number of hours each year.
Prime generators, on the other hand, are designed to handle fluctuating load demands over extended periods. This flexibility makes them suitable for applications where power requirements change throughout the day.
Understanding the differences between standby, prime, and continuous power generators is essential when selecting the right natural gas generator for your specific application and operating environment.
Natural gas generators have numerous advantages that contribute to their widespread adoption:
Natural gas is a relatively clean-burning fuel compared to diesel or gasoline. It produces less pollutant emissions such as nitrogen oxides and particulate matter.
Natural gas prices are generally more stable than diesel or gasoline. This results in more predictable operating costs over the lifetime of the generator.
Due to the properties of natural gas and advanced engine technology, natural gas engines can achieve high levels of efficiency.
Compared to diesel generators, natural gas generators are quieter and suitable for a variety of environments, including residential areas.
Natural gas generators can start and reach full power output quickly, which is critical in scenarios requiring immediate backup power.
Lower natural gas emissions help reduce environmental impact and can help organizations meet sustainability goals and regulatory requirements.
As we mentioned earlier, the biggest competitor to natural gas backup generators is the diesel generator. Let’s compare these two types of generators and see their respective advantages and disadvantages:
Storage: Diesel fuel has a maximum storage life of only 24 months, and large-scale storage is very costly. Natural gas generators do not require refueling. Advantage: Natural Gas
Cost: Natural gas generator sets have lower purchase costs, and natural gas itself is the cheaper of the two fuels, but installation costs are higher due to the need to lay natural gas pipelines. Diesel generators generally have a longer lifespan and require less maintenance, resulting in lower operating costs over their lifespan. (Slight) Advantage: Natural Gas
Safety: Diesel is the least flammable of all generator fuels, while a ruptured natural gas pipeline can easily lead to an explosion. Advantage: Diesel
Ease of Use: Both types of generators can start smoothly in cold environments, but diesel generators are not suitable for humid environments. Diesel generators also have the risk of “wet buildup,” where unburned fuel enters the exhaust system due to prolonged operation of the engine below its design operating temperature. Natural gas generators do not have this problem. Advantages: Natural Gas
Efficiency: Natural gas generators burn clean fuel with virtually no emissions, but diesel generators are more efficient and can provide more usable electricity than the same amount of natural gas. Advantages: Diesel
Environmental Impact: While natural gas generators also emit carbon dioxide, diesel exhaust is a well-known toxic air pollutant. Natural gas generators also produce less noise pollution. Learn why natural gas generators are an environmentally friendly choice. Advantages: Natural Gas
If you’re in the market for an industrial power solution, a used natural gas generator can be a practical and cost-effective option. High-quality refurbished generators often deliver reliable performance while offering several key benefits:
Convenience: If your facility is already connected to a municipal natural gas pipeline, installing a natural gas generator is straightforward. The generator receives a continuous fuel supply directly from the gas line, eliminating the need to monitor fuel levels, refill storage tanks, or arrange fuel deliveries.
Environmental Benefits: Purchasing a used generator extends the service life of professionally refurbished equipment, reducing unnecessary waste and maximizing the value of existing resources. It’s an environmentally responsible choice that supports more sustainable equipment utilization.
Cost Savings: A used generator can significantly reduce your initial investment without sacrificing reliability. Refurbished units are typically available at substantially lower prices than new equipment, allowing businesses to save as much as 70% compared to purchasing a brand-new generator.
Once you’ve decided to use natural gas as your power source, the next step is selecting a generator that best matches your operational requirements. To identify the most suitable and efficient natural gas generator for your business, consider the following key specifications:
Emission Rating: Emission compliance is an important factor when choosing a natural gas generator. The U.S. Environmental Protection Agency (EPA) has established increasingly stringent emission standards over the years to reduce air pollution and minimize the environmental impact of power generation equipment. Different generator categories are subject to different regulatory requirements, so it’s essential to choose a model that complies with the latest EPA emission standards. If your business operates in states with stricter environmental regulations, look for generators that are certified by the California Air Resources Board (CARB).
Phase: Natural gas generators are typically available in either single-phase or three-phase configurations. Although both generate alternating current (AC), single-phase generators supply one AC waveform and are generally suitable for residential or light commercial applications. Three-phase generators produce three synchronized AC waveforms, delivering smoother, more consistent power and are better suited for industrial facilities and heavy-duty equipment.
Size: Selecting the correct generator capacity is essential for reliable operation. A generator that is too small may become overloaded, which can reduce performance, damage both the generator and connected equipment, and even create potential safety hazards such as electrical fires. Carefully calculating your total power demand will help ensure you choose a generator with sufficient capacity for both current and future needs.
Soundproof Enclosure:
Although natural gas generators generally operate more quietly than many other generator types, noise reduction may still be an important consideration in certain environments. Continuous exposure to excessive noise can affect workplace comfort and may even pose hearing risks over time. A soundproof enclosure helps minimize operating noise by surrounding the generator with acoustic insulation, making it an ideal option for installations in residential areas, hospitals, schools, hotels, offices, or any location where low noise levels are required.
Properly sizing a natural gas generator is critical to ensuring it can meet the power demands of the intended application.
Here are the key factors to consider:
Power Requirements: Start by evaluating your home or business’s power needs. Calculate the total wattage required to run essential appliances, equipment, and systems during a power outage. This will help you determine the required output power of the generator in kilowatts (kW).
Load type: Different appliances and equipment have different starting and operating power requirements. Some equipment, such as air conditioners and motors, require a higher initial surge to start. Make sure to account for these changes in your calculations.
Single Phase or Three Phase: Determine if your facility requires single or three phase power. Single-phase power is common in homes and small businesses, while larger industrial applications often use three-phase power.
Efficiency of the generator: Consider the efficiency of the generator at different load levels. Generators are most efficient when they are running at around 70-80% of their maximum capacity. Oversizing a generator can result in inefficient operation at low loads.
Future Growth: Anticipate any potential increase in electricity demand due to business expansion or additional equipment. In general, it’s a good idea to plan for some extra capacity.
Local codes and regulations: Check local building codes and regulations that may dictate maximum allowable generator sizes or emission standards.
Installing a natural gas generator is an investment in the future success of your company. To ensure you reap all the benefits of this environmentally friendly, energy-efficient solution, make sure you’re prepared to take on any challenge, including:
Fuel supply issues: Being connected to a local gas line provides the advantage of a reliable fuel supply. However, it’s important to consider that during natural disasters or extreme temperatures, there may be increased demand for natural gas from numerous businesses and households in your area. This could potentially strain the availability of this energy source.
Location: When installing a generator, it is crucial to consider the fuel availability in your area. While some regions like Texas and North Dakota are abundant in natural gas, certain parts of the Northeast face seasonal gas shortages. If you intend to install a natural gas generator in an area susceptible to such shortages or natural disasters, it is vital to have a contingency plan in order to ensure preparedness at all times.
Maintenance needs: Maintenance for natural gas generators is more frequent compared to diesel generators, resulting in higher service costs over a shorter period of time. This is primarily because natural gas generators require spark ignition. However, if you still prefer the advantages of a natural gas model, it is advisable to schedule maintenance during planned outages. This way, you can minimize downtime and resume operations promptly.
A natural gas generator is a dependable and effective option for ensuring power continuity during blackouts and in various scenarios. By comprehending the constituents of a natural gas generator, its operational procedure, and the benefits it offers, individuals and businesses can make well-informed choices when selecting a backup power alternative.
Accurately determining the appropriate size of a generator is an essential aspect of guaranteeing its ability to meet present and future energy requirements in a competent and effective manner. With advancements in technology, natural gas generators are poised to become more sophisticated, thereby offering an even more appealing solution for dependable power generation.
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