The Cogeneration project

As part of a wider energy optimisation initiative, the manufacturer installed a 2G Avus 800e CHP system at its UK production facility. The unit provides reliable onsite electricity while recovering heat to support existing thermal processes, improving overall energy utilisation compared with conventional supply methods.

The CHP system has been integrated with the site’s existing steam infrastructure. Automatic load regulation enables the unit to operate flexibly between 35% and 100% output, adjusting to variable production demand and reducing grid electricity imports during periods of higher load.

Recovered exhaust heat is routed to the existing combination steam boiler to supplement steam generation, while jacket heat is supplied as low-temperature hot water (LTHW) for internal manufacturing processes.

The project was delivered within a tightly managed programme, with just five weeks required on-site and four months from contract signature to beneficial operation. Extensive preparation during the design and planning stages was critical to achieving this efficient installation timeline. Close collaboration between the project delivery team and the client’s project manager ensured smooth coordination throughout the works.

The design, manufacture, and installation of the exhaust ducting required a high degree of precision, with prefabricated sections produced to tolerances of less than 3 mm to accommodate tight spatial constraints. From a process integration perspective, the existing steam boiler infrastructure included an unused waste heat stream, allowing for a straightforward connection to the CHP system and maximising overall efficiency with minimal disruption to operations.

Designed with future adaptability in mind, the CHP installation is fully H₂-ready and compatible with alternative gaseous fuels, supporting long-term flexibility as energy requirements evolve.