A Manufacturer That Combines Diesel Gensets With BESS for Fuel Saving and Higher Efficiency: Inside MPMC’s Hybrid Engineering

Adding a battery to a diesel generator saves the most fuel when both are designed to work together: the generator sized for efficient running, the battery sized to cover peaks and quiet periods, and one control system deciding which does what. MPMC manufactures generator sets, battery energy storage and integrated hybrid power stations in its own factories, so it engineers the combination as one system rather than joining separate products on site.

Why One Manufacturer Delivers Better Hybrid Results

Right-Sized Generators

When a battery covers peaks and motor starts, the generator no longer needs to be oversized. It runs at its optimal load point of around 75%, and stays above the 30% minimum load factor recommended for long-term diesel operation. MPMC product data associates this approach with fuel savings of up to 75% compared with running the generator alone.

Right-sizing also lowers the capital cost of generation and reduces engine wear, because the generator spends its hours in its most efficient operating range instead of idling at light load.

Matched Controls and One Monitoring Platform

HBD-R units parallel with DSE, ComAp, DEIF, Woodward, Smartgen, CAT EMCP and Cummins PCC generator controllers, and MPMC’s self-developed EMS and SCADA manage generators, batteries and solar together, with real-time remote monitoring, automated reports and Starlink satellite backup communication for remote sites.

Because MPMC builds both the generator sets and the batteries, it specifies them together for each project, matching generator size, battery capacity and control logic to the site’s load profile. Generator sets are load-tested at 0% to 110% in MPMC’s CNAS-accredited test centre, and HBD-A systems support VSG, grid-forming and black start modes that let the battery establish site power independently when generators are stood down.

MPMC HBD-R Series battery storage working in parallel with a diesel generator set in a hybrid configuration.

Table 1. MPMC genset-plus-BESS formats

How the EMS Saves Fuel: The Dubai Example

At ten off-grid concrete batching stations in Dubai, each station pairs an HBD-500-1000 with three 500 kVA Perkins-powered gensets to serve a load that peaks at 847.8 kW and averages 409 kW, around the clock at 45-50°C. The EMS runs in three phases: the battery discharges while one genset runs at its optimal 75% load; multiple gensets run in parallel to recharge the battery at up to 500 kW; and all sources stand in mutual redundancy. Each station saves 254.13 litres of fuel a day, 92,757 litres a year, cuts OPEX by about 20%, extends genset life by two to three years and pays back the hybrid investment in two to three years.

Integrated Hybrid Power Stations

For sites that prefer a single unit, MPMC’s GB Series combines a genset and LFP battery in one compact station from 10 kVA to 500 kVA, with the GB-125P offering 250 kW of output from 215 kWh and a 125 kVA genset option, and the GB-250P offering 500 kW from 430.1 kWh with a 250 kVA genset, available with a Scania S5 engine. The GSB Series adds a 2,375 W slide-out solar array, with Perkins, Kubota or Yanmar engines, and up to four units fit in a 20-foot container.

GSB and GB stations are managed by a smart EMS that starts the genset automatically as demand requires and lets the battery and solar array carry the load at other times, making them well suited to camps, offices, monitoring stations and small commercial sites.

MPMC GSB Series hybrid power stations, combining genset, battery storage and slide-out solar, in the factory.

Table 2. Documented results from MPMC genset-plus-BESS systems

Designing a Fuel-Saving Hybrid System With MPMC

• Share your load profile, including peaks and quiet periods

• List existing generators and their controllers

• Note fuel delivery costs and service intervals

• Consider solar or cleaner-fuel options

• Contact MPMC at sales@mpmc-china.com or WhatsApp +86 150 0085 4420 for a hybrid fuel-saving proposal

https://www.mpmc-group.com/
MPMC Powertech Corp.