Case Study: Cost-effective retrofit solutions helps Delhi power generators meet strict emissions standards

Challenge:

Power generators in Delhi and other regions are required to meet increasingly strict emissions regulations. A customer approached Nelson Global looking for a cost-effective retrofit solution that would significantly reduce emissions while also improving noise control and overall performance. The solution needed to integrate seamlessly with existing generator systems without large-scale equipment replacement.

Solution:

Nelson Global engineers developed a complete emission control system through a phased, collaborative approach:

• Phase I: The team created an initial retrofit kit by integrating catalytic components into a single structural unit. This included adding piping, a resonator, and an expansion chamber to help reduce noise levels.
• Phase II: Nelson Global designed and manufactured custom housings for the catalytic components to ensure proper performance and durability within the retrofit system.
• Phase III: Engineers combined all elements into a fully integrated unit, consolidating multiple components into a streamlined, efficient system built around the customer’s existing catalyst technology.

Engineering, operations, and manufacturing teams worked together throughout development to source materials, assemble prototypes, conduct tests, and ensure that the final unit met all regulatory and performance expectations.

Results:

The final retrofit solution delivered:

• Significant reductions in harmful emissions
• Compliance with local regulatory requirements
• Improved fuel efficiency and generator performance
• A cost-effective alternative to purchasing new equipment

Impact:

This project demonstrates Nelson Global’s ability to modernize existing systems with practical, engineered solutions that balance performance, compliance, and cost. By taking a structured, innovative approach, the team provided the customer with a reliable path forward – extending the life of their power generators while helping them meet today’s environmental standards.