Glass Factory 6 MW HFO Power Plant

Project Details

Name	Year	Location	Client	Type	Description	Scope
Glass Factory 6 MW HFO Power Plant	2018	Chtoura, Lebanon	Glasspack	Power Plant	HFO power plant based on four Hyundai engines delivering 24/24 power to a glass factory	Execution of the preliminary and conceptual design

Project Background & Objectives

The Glass Factory 6 MW HFO Power Plant project was initiated to build a dedicated, highly stable captive power generation facility to support intense industrial manufacturing operations in Chtoura, Lebanon. Commissioned by Glasspack, this high-reliability project focused on establishing an independent HFO power plant based on four Hyundai engines capable of delivering continuous, 24/24 power to a glass factory. Within this critical heavy industrial operational framework, PDP Energy was selected to direct the crucial early phase of the facility. The primary company-specific objectives centered on the execution of the preliminary and conceptual design, setting up the core electrical and thermal baseline architecture to protect manufacturing lines against grid instability.

Project Challenges

Designing a 24/7 heavy fuel oil (HFO) generation asset inside an active industrial glass manufacturing campus presents significant thermal, mechanical, and power quality hurdles. Glass production requires absolute thermal and electrical continuity; even a brief voltage dip can freeze raw materials in the furnaces, resulting in catastrophic equipment failure and massive financial losses. PDP Energy had to resolve intense technical challenges, including balancing structural layout constraints for four massive Hyundai engine blocks, optimizing complex heavy fuel handling and pre-heating subsystems, and designing robust fault-ride-through capabilities to handle abrupt industrial motor load variations without disrupting the plant’s delicate operating balance.

Project Outcomes

Operating as the primary conceptual engineering partner, PDP Energy successfully finalized the complete preliminary and conceptual design package for the heavy industrial power asset. The project effectively established an optimized, highly resilient technical framework tailored for high-demand captive industrial operations. By delivering precise mechanical configurations and synchronized load management blueprints, PDP Energy paved the way for the secure installation of the 6 MW power plant, ensuring the manufacturing facility gains complete energy self-sufficiency, maintains uninterrupted production cycles, and isolates its core machinery from external grid disruptions.

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