Consumers Energy Installs Gas Path, Fuel System Tech at Zeeland Gas Plant

Consumers Energy is expanding the Zeeland natural gas-fired power plant, installing an advanced gas path (AGP) system and advanced fuel system (AFS) in preparation for Michigan’s summer peak-generation period. Scheduled for completion in mid-June 2025, the plant’s expansion aims to increase turbine generation capacity and improve performance and fuel flexibility.

"This expansion of our Zeeland facility is a step forward in our commitment to reliability," said Norm Kapala, Vice President of Generation Operations at Consumers Energy. "As demand for electricity continues to evolve, we're taking proactive measures to ensure our customers continue to receive dependable energy around the clock, especially as our communities grow."

The Zeeland power plant’s output and fuel efficiency will be bolstered through an AGP installation, enabling each gas turbine to produce more electricity with quicker demand response. The AFS will control and improve fuel mixing, offering a 2.5% boost in fuel efficiency while adhering to annual emissions regulations. Overall, Consumers Energy’s 6.8 million customers will benefit from an additional 50 MW of power in Michigan’s lower peninsula counties.

These installations fall under the company’s Reliability Roadmap, which outlines infrastructure modernization and improved grid resilience. "This is not just an investment in power generation—it's an investment in Michigan's future," Kapala added. "We're building a stronger, smarter energy grid that protects our communities and supports our state's economic growth."

Covert Generating Station; image credit: Consumers Energy

In addition to increasing power capacity at its Zeeland Generating Station, Consumers Energy is maintaining the Jackson Generating Station and expanding its gas-fired facility portfolio with a recent purchase of the Covert Generating Station. The company also plans to deliver on-demand electricity with the Karn 3 and 4 combined-cycle units.

Covert Generating Station

In early June 2023, Consumers Energy initiated operations at the Covert Generating Station in Van Buren County, Southwest MI, marking a key milestone in its Clean Energy Plan. This initiative aimed to satisfy the state's increasing energy demands in an environmentally responsible manner.The company plans to retire its remaining coal-fueled power plants by mid-2025.

The natural gas-fueled Covert Generating Station boasts a generation capacity of 1,200 MW, capable of serving over a million homes in Michigan. Operational since 2004, the plant's integration into Consumers Energy's portfolio allows for an increase in affordable and reliable power generation without additional greenhouse gas emissions. The Covert plant's workforce, comprising 29 employees, joined Consumers Energy in the course of the transition.

Energy in Michigan

In March 2025, the U.S. Department of Energy granted a second loan disbursement to Holtec for the Palisades Nuclear Plant project: $56,787,300 of up to $1.52 billion was released to restart the commercial nuclear reactor. Once online, the Palisades reactor will generate 800 MW of low-cost, reliable baseload power for Michigan residents. Holtec obtained its first disbursement from the Loan Programs Office (LPO) in September 2024.

The company uses LPO funds to finance the plant’s restart and ensure compliance with Nuclear Regulatory Commission (NRC) standards. The Palisades project is expected to support or retain up to 600 high-quality jobs in Michigan, representing America’s first restart of a commercial nuclear reactor that previously ceased operations. The project is subject to NRC licensing approvals.