Diesel Generators have historically been a large consumer of diesel fuel and producer of emissions.  Because of their physical size and capital cost for initial purchase,  most end-users purchase a unit that is just large enough to do the job with little or no power reserve.  This condition results in the diesel unit being run at or beyond its intended capacity most of the time.


Electrical systems on portable aggregate plants aren’t very efficient.  The average over a sample of about 12 portable plants of various size and design is about 54%, meaning that 46% being generated is “wasted”.  This waste comes from the electrical motors and cables that are running under capacity, for example a jaw crusher has 150 HP electric motor, but is only using 70 amps, therefore a waste of 80 amps that motor is “using” for no purpose.  Conveyors on plants are another culprit, operating at significantly lower HP requirements most of the time.


PowerVault’s patented technology uses capacitors with controllers that continually monitor the system efficiency and then automatically adjust to get the system efficiency to 95% - 99% all of the time.  The result of this action is reduced AMP draw on your generator because the “wasted” amps are now generated by the PowerVault, leaving that capacity available in your generator.  The other obvious benefit from reduced generator loading is reduced fuel consumption.  End-Users are reporting savings from 15% - 35% reduction in fuel consumption.  This product also reduces green house gas emissions and some producers may find opportunity in carbon tax credits.

How It Works

Adding capacitors to the distribution network is the ultimate way to provide reactive compensation and bring the power factor to a more suitable level.  The capacitors act as a storage device for reactive power which reduces the reactive power that the generator has to provide to the distribution network and in turn improves the power factor of the system.

The picture below shows the Reactive power in blue, which is the power being used up for no real value.  As you can see with the addition of capacitors, the reactive power is being replaced by the capacitor which frees up available active power.

If you are interested in discussing this system for your plant, we would be happy to do so.  We can come out and do an analysis of your plant and make recommendations based on the findings.  We also have Demo units available and of course a list of clients for you to talk to.