Post on 02-Aug-2020
THE ENERGY GENERATION
Cogeneration
ISO 9001:2008 ISO 14001:2004 SOA RINA
INTERGEN / COGENERATION 3
installed power
1700+ MWe
installed plants in Italy
260+
sole distributor
in Italy for
since 1987
gas units range
from 100 to 4300 kWe
Intergen, a long history
Intergen has been operating in the energy market for almost 70 years. The Hotel Gallia
in Milan was one of its first customers, purchasing a generating set in 1945. Intergen has
also been designing and building cogeneration and trigeneration plants for prestigious
customers for 30 years. A team of skilled engineers manages the whole process, from the
analysis of the customer requirements to the preliminary design, building, testing and final
commissioning of the plant. The quality of all the assembled components is ensured under
commercial agreements with important partners worldwide. Intergen also offers a qualified
aftersales service, technical assistance and full-time maintenance service aimed at minimizing
plant lifecycle costs.
Mission vision and values
Intergen is a leading player in the construction of Combined Heat & Power plants. Continuous
upgrading of employees’ technical skills and attention to customer’s needs guarantee the
product’s quality and reliability. Intergen is the synthesis of experience, tradition, forward
lookingness and innovation.
Intergen adopts the principle that companies are first and foremost men, women and ideas.
People with long experience, enthusiastic, creative young people and high-level specialists
united by a passion for their work and the vision of a more liveable, advanced and informed
world. The ongoing commitment of everyone in the company guarantees that excellence, the
key to continuity and market growth, is achieved. Intergen adopts operating policies that fully
respect the person, the territory, the environment and safety at work.
Since 2004 Intergen holds quality certification:
We are members of:
› cogeneration plants› trigeneration plants› gas generating sets› service & maintenance
e�cientcogeneration
www.intergen.itinfo@intergen.it
THE ENERGYGENERATION
43% ENERGIA ELETTRICA
44% ENERGIA TERMICA
13% PERDITE
INTERGEN / COGENERATION4 5
Cogeneration enables the simultaneous production of electricity and heat in a single system
from a single source of fuel, whether fossil or renewable. The production of electricity and heat
in separate processes does not generally allow the heat produced by the combustion process
to be used, and it is therefore dissipated into the environment. Cogeneration, on the other
hand, allows the heat produced by the combustion process to be recovered and used, ensuring
a more efficient use of the raw fuel source. A good example of cogeneration is the production
of electricity using a generating set with an endothermic engine coupled to an alternator.
The heat generated by the endothermic engine’s combustion process is recovered by means
of heat exchangers to produce thermal energy such as:
The use of the recovered heat allows systems to be called “cogeneration” if only heat and
power are generated, and “trigeneration” if cooling, heat and power are generated; in general
an overall increase in the system’s performance is achieved.
Cogeneration
Energy efficiency
Using a cogeneration plant for industrial or residential applications results in savings in raw
energy up to 30% compared to the separate generation of electricity and heat, which can
be fully used in many different processes. Combined production of electricity and heat cuts
significantly the electricity bill, allowing companies to gain a real competitive edge; another
important effect is the considerable reduction in gas emissions which contributes greatly
to environmental protection. Intergen provides turnkey design and installation of systems
using high efficiency engines with a total efficiency that can exceed 87%; this translates
into higher cost savings, thus guaranteeing a fast return on investment.
Service network
know-howOne of the few Italian
companies to have a structured
organization with a team
of 30 in-house engineers.
a qualifiedteam
availabilityWe can intervene promptly,
7/7, 365 days/year,
throughout Italy.
capillarityThe central warehouse
guarantees shipment of spare
parts to the decentralized
storerooms at the plants
within 24 hours.
availabilityThe display and monitoring
of all the operating parameters
both in running conditions
and in the case of a malfunction
maximizes the availability
of the plant.
immediate intervention
availabilityspare parts
remote controlof the plant
Intergen offers a maintenance service for both engines
and plants through an internal structure which can provide
the service 7/7 365 days/year.
Intergen currently manages the maintenance of more than
180 plants, thanks to in-house engineers and a network
of authorized workshops throughout Italy, making it one
of the leading operators in this sector.
Accurate planning of on-site activities and continuous training
of the service personnel enable correct performance of all
operations required to optimize the plant’s performance
and maintain it in excellent operating conditions.
Intergen also offers a remote control system with installation
of a modem on site for web communication, enabling
the display and monitoring of all the operating parameters,
both in normal running conditions and in the event of plant
malfunction / shutdown.
› hot water and/or steam for residential or industrial applications;› refrigerated water by means of absorbtion type chillers.
30+%
87+%
savings in primary energy
total efficiency
43.5% electrical energy
13.0% losses
43.5% thermal energy
energy introduced by the fuel
100% cogeneration plant
immediate intervention 7/7 365 days/year
INTERGEN / COGENERATION6 7
Cogeneration plants in pre-fabricated sound proof canopies
A highlight of Intergen’s plants is the customized construction of cogeneration plants assembled
on site. The pre-fabricated panelled canopy significantly reduces noise while maintaining compactness
and accessibility for easy operation and maintenance. This construction method is used for large plants
installed outside factories and production sites.
1 Segregated transformer room
2 Command & control room
3 Medium voltage switchgear room
4 Ancillary panels (neutral point resistor,
control unit, MWM TEM engine control panel)
5 Air intake section
6 Air expulsion section fitted with ATEX fans
7 MWM engine-alternator unit
8 Access and maintenance platform
9 Radiator connection piping
and fluid circulation skid
10 Fluid circulation skid complete with pumps,
heat exchangers and regulation system
11 Compressed air motor starting system
12 Oxidizer catalyst
13 Exhaust gas line and silencer
14 Walkways and radiator and catalyst area access
15 Emergency air cooler
16 Sound proof enclosure with access and removable
panels for unscheduled maintenance activities12 3
4
5
6
8
79
13
10
14
11
15
12
16
1560 kWe cogeneration plant
prefabricated sound proof enclosure
4300 kWe cogeneration plant
prefabricated sound proof enclosure
INTERGEN / COGENERATION8 9
Cogeneration plants in containers
Intergen designs and installs cogeneration plants in containers, pre-assembling most of the components
in the factory; the modular composition of several containers covers any power need.
This solution guarantees maximum construction compactness and a reduction in the on-site installation
and commissioning time thanks to a final inspection test carried out in the factory.
1 Cogenerator and accessory container
2 Electrical container (command and control board /
transformer / medium voltage)
3 Emergency air coolers
4 Silencers
5 Heat recovery boiler
6 Walkways and access to boiler and radiator area
7 Waste and fresh oil storage system
8 Fluid circulation skid complete with pumps,
heat exchangers and regulation system
9 SCR system (selective catalytic reactor)
for NOX/ CO reduction
10 Command and control panel room
11 Transformer (low voltage/medium voltage)
12 Medium voltage switch gear
1560 kWe
cogeneration plant
in container
1
2
3
4
5
6
7
8
9
10 1112
2000 kWe
cogeneration plant
in container
INTERGEN / COGENERATION10 11
Cogeneration plants in buildings
Intergen designs and installs cogeneration plants inside existing or new buildings, assembling
all the components on site and designing a customized solution to optimize the available space.
This approach allows unused spaces to be exploited and minimizes the authorization process.
Intergen can offer consultancy at the estimate stage to find, together with the customer, the best
solution for the system (environmental impact, noise, etc.).
1 Cogeneration plant
2 Absorption chiller unit
3 Silenced cooling tower
4 Refrigeration unit/cooling tower water pumps skid
5 Fresh and waste oil storage system
6 Sound proofed air intake and expulsion ducts
7 Fluid circulation skid complete with pumps,
heat exchangers and regulation system
8 Emergency air coolers
2000 kWe
cogeneration plant
in a building6
87
1
2
3
4
5
1200 kWe trigeneration plant
in a building
2450
2450
3000
3252
2990
2497
1000
0
2510
3000
12000
12634
1450
imlgroup
2450
2450
3000
3252
2990
2497
1000
0
2510
3000
12000
12634
1450
imlgroup
300
0
642
0
21700 1985
309
0
1000
0
295
0
imlgroup imlgroup
imlgroup
17700 5605
23250
177005150
4000 6505 12700
1300
9190
6670
9310
1163
0
9860
3000
6850
imlgroup
5580
3000
2580
1055
5
2950
17740
660011120 1450
2250
452024
97
imlgroupimlgroup imlgroup
5580
3000
2580
1055
5
2950
17740
660011120 1450
2250
452024
97
imlgroupimlgroup imlgroup
INTERGEN / COGENERATION12
1 Cogenerator
and accessory container
2 Medium voltage, Transformer
3 Waste and fresh
oil storage system
—
Intergen painting: RAL 5017 Traffic blue
1 Cogenerator and accessory
container, Transformer
2 Waste and fresh
oil storage system
—
Intergen painting: RAL 5017 Traffic blue
1 Cogenerator and accessory
container, Transformer
2 Waste and fresh
oil storage system
—
Intergen painting: RAL 7032 Pebble grey
1 Cogenerator and accessory
container, Medium voltage,
Transformer
2 Heat recovery boiler
—
Intergen painting: RAL 7032 Pebble grey
1
1 2
2 3
2
1
1 2
The layout of thecogeneration plants
› plant power 600 / 800 kWe
› plant power 3200 / 4300 kWe
› plant power 1200 / 1560 kWe
› plant power 2000 kWe
electrical power COP according to ISO 8528-1
fuel consumption
fuel consumption
electrical e�ciency
thermal e�ciency
total e�ciency
400
950
93
42,1
45,4
87,5
[kW]
[kW]
Nm3/h
[%]
[%]
[%]
600
1.433
141
41,9
46,0
87,9
800
1.891
186
42,3
45,5
87,8
1.000
2.326
229
43,0
44,8
87,8
1.200
2.750
270
43,6
43,3
86,9
1.560
3.608
355
43,2
43,8
87,0
2.000
4.577
450
43,7
43,2
86,9
3.333
7.645
752
43,6
42,9
86,5
4.300
9.810
965
43,8
43,0
86,8
exhaust gas �ow rate (wet)
exhaust gas temperature
NOX (5%O
2)
CO (5%O2) with catalytic oxidizer
2.186
457
500
< 300
[kg/h]
[°C]
[mg/Nm3]
[mg/Nm3]
3.299
459
500
< 300
4.360
459
500
< 300
5.428
412
500
< 300
6.488
414
500
< 300
8.530
420
500
< 300
10.851
414
500
< 300
17.778
447
500
< 300
22.761
456
500
< 300
engine jacket water
and lube oil circuit heat
intercooler circuit heat
exhaust heat
after heat exchanger
saturated steam �ow rate, 8 bar
cold water production (from jacket
water and lube oil circuit heat)
cold water production (from jacket
water, lube oil and exhaust gas heat)
[kW]
[kW]
[kW]
[kg/h]
KWf
KWf
con�guration/no. of cylinders
speed
lube oil consumption
starting system
alternator voltage
Marelli alternator model
genset dry weight
genset footprint [L x D]
genset height [H]
V08
1.500
0,2
400
MJB 355 MB4
5.340
3,1x1,6
2,2
giri/min.
g/kWh
V (+/- 10%)
[kg]
[m]
[m]
V12
1.500
0,2
400
MJB 400 LC4
7.000
3,7x1,6
2,2
V16
1.500
0,2
400
MJB 450 MB4
8.450
4,2x1,6
2,2
V12
1.500
0,2
400
MJB 500 MB4
11.700
4,8x1,8
2,2
V16
1.500
0,2
400
MJB 500LA4
13.320
5,5x1,8
2,2
V20
1.500
0,2
400
MJB 560 LB4
17.900
6,2x1,7
2,2
V12
1.000
0,2
11 KV
MJH 800 MB6
43.100
7,9x2,6
3,4
V16
1.000
0,2
11 KV
MJH 800 MC6
51.200
9,4x2,6
3,4
maintenance interval
hours before major overhaul (TBO)
2.000
64.000
h
h
2.000
64.000
2.000
64.000
4.000
64.000
4.000
64.000
4.000
64.000
4.000
80.000
4.000
80.000
24.246
285
500
< 300
V16
1.000
0,2
11 KV
MJH 800 MC6
51.200
9,4x2,6
3,4
Electrical
PERFORMANCE TCG2016 TCG2020 TCG2032
VO8 C V12 C V16 C V12 M V12 V16 V20 V12 V16
4.500
10.154
998
44,3
43,5
87,8
V16 B
HEAT RECOVERY
EMISSIONS
MOTOR/ALTERNATOR DATA
MAINTENANCE
Pneumatic
NATURAL GAS
205
25
226
310
154
323
315
41
343
470
236
494
407
56
454
620
305
646
559
67
483
640
419
782
609
106
582
770
457
893
799
133
781
1.040
599
1.185
1.005
178
972
1.290
754
1.483
1.502
297
1.779
2.410
1.127
2.461
1.873
359
2.346
3.200
1.405
3.164
2.474
268
1.945
2.510
1.856
3.314
V12 M
1.500
0,15
400
MJB 450 LB4
10.850
4,8x1,8
2,2
4.000
80.000
4.000
80.000
REFERENCE CONDITIONS
› Methane number: 80
› PCI: 10 kWh/Nm3
› combustion air temperature: 25°C
› combustion air humidity: 60%
› installation altitude: 100 m (slm)
› data sheets for di§erent environmental/altitude
conditions are available on request
NOTES
1 the 250 NOX version is available – 2 heat power data are subject to a tolerance of ± 8% – 3 fuel consumption data are subject to a tolerance of +5% –
4 data referred to 100% load (data for partial loads are available) – 5 exhaust heat after heat exchanger with cooling to 120°C – 6 heat power with
water/glycol solution at 35% – 7 steam production at 8 barg with economizer and water feeding at 80°C – 8 data for the production of cold water at
7-12°C with COP=0,75 – 9 the exhaust gas temperature �gures are subject to a tolerance of ±25°C – 10 for the 2032 series, 6.3 kV alternators are also
available – 11 medium voltage alternators are available on request for the 2020 series – 12 data for 50 Hz alternators, 60 Hz also available on request –
13 the 2032V12 cogenerator calibrated at 250 mg/Nm3 of NOx is rated to 3201 Kwe electrical power – 14 the maintenance plan for the 2016 motor
requires only a valve clearance check at 2000 h.
—
general note the heat recovery data shown are to be con�rmed during engineering stage
general note the technical data are subject to modi�cation by the manufacturer
(10, 11, 12)
(3)
(3)
(4)
(1)
(14) (14) (14)
(13)
(2, 8)
(2)
(2, 5)
(6)
(7)
(7)
giri/min.
g/kWh
V (+/- 10%)
[kg]
[m]
[m]
electrical power COP according to ISO 8528-1
fuel consumption
fuel consumption
electrical e�ciency
thermal e�ciency
total e�ciency
400
940
169
42,5
40,4
82,9
[kW]
[kW]
Nm3/h
[%]
[%]
[%]
600
1.412
254
42,5
40,6
83,1
800
1.878
338
42,6
40,5
83,1
1.000
2.361
424
42,4
41,7
84,1
1.200
2.804
504
42,8
41,1
83,9
1.560
3.683
662
42,4
41,5
83,9
2.000
4.669
839
42,8
41,6
84,4
engine jacket water and lube oil circuit heat
exhaust heat after heat exchanger
214
166
319
254
429
333
522
462
631
522
850
678
1.075
870
[kW]
[kW]
PERFORMANCE TCG2020
VO8 C V12 C V16 C V12 M V12 V16 V20
HEAT RECOVERY
exhaust gas �ow (wet)
exhaust gas temperature
NOX (5%O
2)
CO (5%O2) with catalytic oxidizer
2.164
429
500
< 300
[kg/h]
[°C]
[mg/Nm3]
[mg/Nm3]
3.249
434
500
< 300
4.320
430
500
< 300
5.248
464
500
< 300
6.341
446
500
< 300
8.282
444
500
< 300
10.558
446
500
< 300
EMISSIONS
con�guration/no. of cylinders
speed
lube oil consumption
starting system
alternator voltage
Marelli alternator model
genset dry weight
genset dimensions [L x D]
genset height dimensions [H]
MOTOR/ALTERNATOR DATA
BIOGAS
(3)
(3)
(2)
(1)
(2, 5)
(4)
REFERENCE CONDITIONS
› data valid for biogas with 55% CH4
(data sheets available for biogas 65% CH4)
› Methane number: 141
› PCI: 5,6 kWh/Nm3
› combustion air temperature: 25°C
› combustion air humidity: 60%
› installation altitude: 100 m asl
› data sheets for di¡erent environmental/altitude
conditions are available on request
NOTES
1 the 250 and 500 NOX versions are available – 2 heat power data are subject to a tolerance of ± 8% – 3 fuel consumption data
are subject to a tolerance of +5% – 4 data referred to 100% load (data for partial loads are available in the o�cial data sheets) –
5 exhaust heat after heat exchanger with cooling to 120°C. – 6 the exhaust gas temperature �gures are subject to a tolerance of ±25°C
_
general note the heat recovery data shown are to be con�rmed during engineering stage
general note the technical data are subject to modi�cation by the manufacturer
_
the technical data sheets are available on request for gas of di¡erent composition (BIOGAS from ORGANIC FRACTION OF URBAN SOLID WASTE,
BIOGAS from LANDFILL, other gases). Di¡erent gas are subject to veri�cation of MWM Technical Department.
(6)
V08
1.500
0,1
400
MJB 355 MB4
5.340
3,1x1,6
2,2
V12
1.500
0,1
400
MJB 400 LC4
7.000
3,7x1,6
2,2
V16
1.500
0,1
400
MJB 450 MB4
8.450
4,2x1,6
2,2
V12
1.500
0,15
400
MJB 450 LB4
10.850
4,8x1,8
2,2
V12
1.500
0,2
400
MJB 500 MB4
11.700
4,8x1,8
2,2
V16
1.500
0,2
400
MJB 500 LA4
13.320
5,5x1,8
2,2
V20
1.500
0,2
400
MJB 560 LB4
17.900
6,2x1,7
2,2
Electrical
INTERGEN / COGENERATION14 15
Cogenerator range with MWM motors
INTERGEN / COGENERATION16 17
Control and monitoring systems
Command and control panels, panels for medium voltage connection and monitoring
systems. Intergen completes its supply of cogeneration plants with the development
and construction of command, control and power panels designed upon customers’ specific
requirements, both hardware and software. Same engineering for the PLC software, plant
monitoring graphics and the HMI interfaces.
The panel and monitoring functions can be accessed from remote by means of a modem
or cable interface and allow complete replication of the data and information in other user
locations as well as by Intergen, which is strategic in the after-sales and maintenance stages.
development for:› PLC software› monitoring graphics› HMI interfaces
remote functions:› via modem › cable interface
Production plantand test benches
› 3 6-axle trucks
for transport and handling
of 80 t load
› 1 fixed resistive bench
for power tests up to 2 MWe
› 1 6-axle truck
for transport and handling
of 40 t load
› 1 soundproof test room
for testing 3 units
for a total power of 2 MWe
› 2 soundproof test rooms
for testing units
up to 5 MWe each
› 2 mobile resistive benches
for power tests up to 6 MWe
› 2 mobile tanks, 6 m3,
complete with instruments
for consumption tests
Out of a total surface area of over 33000 m2, Intergen has a covered production space of 9000 m2 and an area
of 8000 m2 used for external assembly and tests. The plant disposes of:
The production facility has 2 overhead travelling cranes 30 t each,
for handling purposes. The current production capacity allows more
than 80 units to be built and tested per year.
PAPERMILL
PHARMACEUTICAL INDUSTRY
HOSPITAL BUILDING MATERIALS PRODUCTION INDUSTRY
FOODINDUSTRY
CERAMIC/BUILDING INDUSTRY
FOODINDUSTRY
CHEMICAL INDUSTRY
CERAMIC/BUILDING INDUSTRY
CHEMICAL INDUSTRY
WOOD
FOODINDUSTRY
CHEMICAL INDUSTRY
HOSPITAL DATA CENTER
PAPERMILL
TEXTILE INDUSTRY
2 x 1200 kWe, 2 x 600 kWe 1 x 1560 kWe
3 x 3900 kWe 1 x 1200 kWe
1 x 3200 kWe, 1 x 1200 kWe 1 x 1560 kWe
2 x 4300 kWe, 1 x 3200 kWe 1 x 1200 kWe
4 x 3900 kWe 1 x 1560 kWe
1 x 800 kWe 1 x 4300 kWe
1 x 2000 kWe 1 x 1200 kWe
1 x 2000 kWe 1 x 2000 kWe
1 x 600 kWe 1 x 1200 kWe
INTERGEN / COGENERATION18 19
Who has chosenIntergencogeneration
1700+ 260+ 180+MWe installed worldwide
plants installed in Italy
service contracts
CARTIERAPONTEDORO
PAPERMILL
THE ENERGY GENERATION
2000
/6 IG
E 06
/17
headquartersvia Garçia Lorca, 25I-23871 Lomagna (LC)
sales departmentph: +39 039 5914800
service & maintenanceph: +39 039 5914435
administrationph: +39 039 5914469
www.intergen.itinfo@intergen.it