THE ENERGY

GENERATION

Cogeneration
 INTERGEN / COGENERATION 3

THE ENERGY www.intergen.it

Intergen,
a long history
GENERATION info@intergen.it

efficient 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

cogeneration 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.

› cogeneration plants
› trigeneration plants installed power sole distributor
› gas generating sets 1700+ MWe in Italy for
since 1987
› service & maintenance
installed plants in Italy gas units range
260+ from 100 to 4300 kWe

We are members of: 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:

ISO 9001:2008 ISO 14001:2004 SOA RINA

4 INTERGEN / COGENERATION 5

Cogeneration Service network

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 a qualified immediate availability remote control
to be used, and it is therefore dissipated into the environment. Cogeneration, on the other team intervention spare parts of the plant
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:

› hot water and/or steam for residential or industrial applications;

› refrigerated water by means of absorbtion type chillers. know-how
One of the few Italian
The use of the recovered heat allows systems to be called “cogeneration” if only heat and companies to have a structured
power are generated, and “trigeneration” if cooling, heat and power are generated; in general organization with a team
an overall increase in the system’s performance is achieved. of 30 in-house engineers.
availability
We can intervene promptly,
7/7, 365 days/year,
throughout Italy.
capillarity
The central warehouse
guarantees shipment of spare
parts to the decentralized
storerooms at the plants
within 24 hours.
availability
The 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.

43.5%
43%
electrical energy
ENERGIA ELETTRICA

energy
introduced
Intergen offers a maintenance service for both engines
13.0% losses
by the fuel cogeneration plant
13% PERDITE and plants through an internal structure which can provide
100%
the service 7/7 365 days/year.
43.5%
44% energy
thermal
ENERGIA TERMICA
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.
Energy efficiency immediate
Accurate planning of on-site activities and continuous training
Using a cogeneration plant for industrial or residential applications results in savings in raw of the service personnel enable correct performance of all intervention
savings energy up to 30% compared to the separate generation of electricity and heat, which can operations required to optimize the plant’s performance
30+% in primary 7/7 365 days/year
be fully used in many different processes. Combined production of electricity and heat cuts and maintain it in excellent operating conditions.
energy
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 Intergen also offers a remote control system with installation
to environmental protection. Intergen provides turnkey design and installation of systems of a modem on site for web communication, enabling
total
87+% efficiency
using high efficiency engines with a total efficiency that can exceed 87%; this translates the display and monitoring of all the operating parameters,
into higher cost savings, thus guaranteeing a fast return on investment. both in normal running conditions and in the event of plant
malfunction / shutdown.
6 INTERGEN / COGENERATION 7

Cogeneration plants
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

in pre-fabricated installed outside factories and production sites.

sound proof canopies

4300 kWe cogeneration plant 13 1560 kWe cogeneration plant

prefabricated sound proof enclosure prefabricated sound proof enclosure
14
15

12

1 Segregated transformer room 10 Fluid circulation skid complete with pumps,

9 2 Command & control room heat exchangers and regulation system
5 7 10 11
3 Medium voltage switchgear room 11 Compressed air motor starting system
4 Ancillary panels (neutral point resistor, 12 Oxidizer catalyst
8 control unit, MWM TEM engine control panel) 13 Exhaust gas line and silencer
5 Air intake section 14 Walkways and radiator and catalyst area access
6 Air expulsion section fitted with ATEX fans 15 Emergency air cooler
16 4 7 MWM engine-alternator unit 16 Sound proof enclosure with access and removable
2 1 3
8 Access and maintenance platform panels for unscheduled maintenance activities
9 Radiator connection piping
and fluid circulation skid
8 INTERGEN / COGENERATION 9

Cogeneration plants
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

in containers and commissioning time thanks to a final inspection test carried out in the factory.

2000 kWe 1560 kWe

cogeneration plant cogeneration plant
in container in container

9
4

10 12
8 11

1 Cogenerator and accessory container 7 Waste and fresh oil storage system

3 2 Electrical container (command and control board / 8 Fluid circulation skid complete with pumps,

7 transformer / medium voltage) heat exchangers and regulation system

6 3 Emergency air coolers 9 SCR system (selective catalytic reactor)

1 4 Silencers for NOX / CO reduction
5 Heat recovery boiler 10 Command and control panel room
6 Walkways and access to boiler and radiator area 11 Transformer (low voltage/medium voltage)
12 Medium voltage switch gear
2
10 INTERGEN / COGENERATION 11

Cogeneration plants
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.

in buildings Intergen can offer consultancy at the estimate stage to find, together with the customer, the best
solution for the system (environmental impact, noise, etc.).

3
2000 kWe
1200 kWe trigeneration plant cogeneration plant
2 in a building 6 in a building

7
8

4
5

1 Cogeneration plant 6 Sound proofed air intake and expulsion ducts

1 2 Absorption chiller unit 7 Fluid circulation skid complete with pumps,

3 Silenced cooling tower heat exchangers and regulation system
4 Refrigeration unit/cooling tower water pumps skid 8 Emergency air coolers
5 Fresh and waste oil storage system
12 INTERGEN / COGENERATION

The layout of the › plant power

2000 kWe
cogeneration plants 1 Cogenerator and accessory

10000
container, Transformer
2 Waste and fresh

6420
oil storage system
— imlgroup imlgroup

imlgroup

3000
Intergen painting: 1 2
RAL 7032
› plant power Pebble grey
21700 1985
600 / 800 kWe
1 Cogenerator

10000 10000

3090
and accessory container

2950
2 Medium voltage, Transformer
3 Waste and fresh
oil storage system
3000 3000

2510 2510
3000 3000
imlgroup

— 2 1 3

Intergen painting: imlgroup

RAL 5017
Traffic blue 2450 12000 1450

2450 12000 1450

3252 3252

2497 2497
2990 2990
› plant power
2450 12634 3200 / 4300 kWe
1 Cogenerator and accessory
2450 12634

1300
container, Medium voltage,
Transformer

9190
2 Heat recovery boiler 1 imlgroup

6670
› plant power

Intergen painting:
RAL 7032
1200 / 1560 kWe Pebble grey 2

10555
2580

1 Cogenerator and accessory

10555
5605 17700
container, Transformer
5580

2580

2 Waste and fresh 4000 6505 12700

oil storage system
3000

imlgroup imlgroup imlgroup

5580

—
Intergen painting:

3000
3000

imlgroup imlgroup imlgroup

RAL 5017 1 2
Traffic blue 11120 6600 1450
17740 2250

11630
9310

9860
11120 6600 1450
17740 2250

6850
2950

2497
4520
2950

2497

5150 17700
4520

23250
14 INTERGEN / COGENERATION 15

Cogenerator range NATURAL GAS

PERFORMANCE (4) TCG2016 TCG2020 TCG2032

with MWM motors electrical power COP according to ISO 8528-1

fuel consumption (3)

[kW]

[kW]
VO8 C

400

950
V12 C

600

1.433
V16 C

800

1.891
V12 M

1.000

2.326
V12

1.200

2.750
V16

1.560

3.608
V20

2.000

4.577
V12

3.333 (13)

7.645
V16

4.300

9.810
V16 B

4.500

10.154

fuel consumption (3) Nm3/h 93 141 186 229 270 355 450 752 965 998

electrical efficiency [%] 42,1 41,9 42,3 43,0 43,6 43,2 43,7 43,6 43,8 44,3

thermal efficiency [%] 45,4 46,0 45,5 44,8 43,3 43,8 43,2 42,9 43,0 43,5

BIOGAS total efficiency [%] 87,5 87,9 87,8 87,8 86,9 87,0 86,9 86,5 86,8 87,8

PERFORMANCE (4) TCG2020 HEAT RECOVERY

VO8 C V12 C V16 C V12 M V12 V16 V20 engine jacket water (2, 8) [kW] 205 315 407 559 609 799 1.005 1.502 1.873 2.474
and lube oil circuit heat
electrical power COP according to ISO 8528-1 [kW] 400 600 800 1.000 1.200 1.560 2.000
intercooler circuit heat (2) [kW] 25 41 56 67 106 133 178 297 359 268
fuel consumption (3) [kW] 940 1.412 1.878 2.361 2.804 3.683 4.669

fuel consumption (3) Nm3/h 169 254 338 424 504 662 839 exhaust heat (2, 5) [kW] 226 343 454 483 582 781 972 1.779 2.346 1.945
after heat exchanger
electrical efficiency [%] 42,5 42,5 42,6 42,4 42,8 42,4 42,8
saturated steam flow rate, 8 bar (6) [kg/h] 310 470 620 640 770 1.040 1.290 2.410 3.200 2.510
thermal efficiency [%] 40,4 40,6 40,5 41,7 41,1 41,5 41,6

total efficiency cold water production (from jacket (7)

KWf 154 236 305 419 457 599 754 1.127 1.405 1.856
[%] 82,9 83,1 83,1 84,1 83,9 83,9 84,4
water and lube oil circuit heat)

cold water production (from jacket (7)

KWf 323 494 646 782 893 1.185 1.483 2.461 3.164 3.314
HEAT RECOVERY
water, lube oil and exhaust gas heat)
engine jacket water (2) [kW] 214 319 429 522 631 850 1.075
and lube oil circuit heat
EMISSIONS
exhaust heat after heat exchanger (2, 5) [kW] 166 254 333 462 522 678 870 exhaust gas flow rate (wet) [kg/h] 2.186 3.299 4.360 5.428 6.488 8.530 10.851 17.778 22.761 24.246

exhaust gas temperature [°C] 457 459 459 412 414 420 414 447 456 285
EMISSIONS
NOX (5%O2) (1) [mg/Nm3] 500 500 500 500 500 500 500 500 500 500
exhaust gas flow (wet) [kg/h] 2.164 3.249 4.320 5.248 6.341 8.282 10.558
CO (5%O2) with catalytic oxidizer [mg/Nm3] < 300 < 300 < 300 < 300 < 300 < 300 < 300 < 300 < 300 < 300
exhaust gas temperature (6) [°C] 429 434 430 464 446 444 446

NOX (5%O2) (1) [mg/Nm ] 3

500 500 500 500 500 500 500 MOTOR/ALTERNATOR DATA

CO (5%O2) with catalytic oxidizer [mg/Nm3] < 300 < 300 < 300 < 300 < 300 < 300 < 300 configuration/no. of cylinders V08 V12 V16 V12 M V12 V16 V20 V12 V16 V16

speed giri/min. 1.500 1.500 1.500 1.500 1.500 1.500 1.500 1.000 1.000 1.000
MOTOR/ALTERNATOR DATA
lube oil consumption g/kWh 0,2 0,2 0,2 0,15 0,2 0,2 0,2 0,2 0,2 0,2
configuration/no. of cylinders V08 V12 V16 V12 V12 V16 V20
starting system Electrical Pneumatic
speed giri/min. 1.500 1.500 1.500 1.500 1.500 1.500 1.500
alternator voltage (10, 11, 12) V (+/- 10%) 400 400 400 400 400 400 400 11 KV 11 KV 11 KV
lube oil consumption g/kWh 0,1 0,1 0,1 0,15 0,2 0,2 0,2
Marelli alternator model MJB 450
MJB 355 MJB 400 MJB 450 MJB 500 MJB 500 MJB 560 MJH 800 MJH 800 MJH 800
starting system Electrical MB4 LC4 MB4 LB4 MB4 LA4 LB4 MB6 MC6 MC6

genset dry weight [kg] 5.340 7.000 8.450 10.850 11.700 13.320 17.900 43.100 51.200 51.200
alternator voltage V (+/- 10%) 400 400 400 400 400 400 400
genset footprint [L x D] [m] 3,1x1,6 3,7x1,6 4,2x1,6 4,8x1,8 4,8x1,8 5,5x1,8 6,2x1,7 7,9x2,6 9,4x2,6 9,4x2,6
Marelli alternator model
MJB 355 MJB 400 MJB 450 MJB 450 MJB 500 MJB 500 MJB 560
MB4 LC4 MB4 LB4 MB4 LA4 LB4 genset height [H] [m] 2,2 2,2 2,2 2,2 2,2 2,2 2,2 3,4 3,4 3,4

genset dry weight [kg] 5.340 7.000 8.450 10.850 11.700 13.320 17.900
MAINTENANCE
genset dimensions [L x D] [m] 3,1x1,6 3,7x1,6 4,2x1,6 4,8x1,8 4,8x1,8 5,5x1,8 6,2x1,7
maintenance interval h 2.000 (14) 2.000 (14) 2.000 (14) 4.000 4.000 4.000 4.000 4.000 4.000 4.000

genset height dimensions [H] [m] 2,2 2,2 2,2 2,2 2,2 2,2 2,2
hours before major overhaul (TBO) h 64.000 64.000 64.000 80.000 64.000 64.000 64.000 80.000 80.000 80.000

REFERENCE CONDITIONS NOTES REFERENCE CONDITIONS NOTES

› 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 different environmental/altitude
conditions are available on request
1 the 250 and 500 NOX versions are available – 2 heat power data are subject to a tolerance of ± 8% – 3 fuel consumption data › Methane number: 80 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% –
are subject to a tolerance of +5% – 4 data referred to 100% load (data for partial loads are available in the official data sheets) – › PCI: 10 kWh/Nm3 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
5 exhaust heat after heat exchanger with cooling to 120°C. – 6 the exhaust gas temperature figures are subject to a tolerance of ±25°C › combustion air temperature: 25°C 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
_ › combustion air humidity: 60% 7-12°C with COP=0,75 – 9 the exhaust gas temperature figures are subject to a tolerance of ±25°C – 10 for the 2032 series, 6.3 kV alternators are also
general note the heat recovery data shown are to be confirmed during engineering stage › installation altitude: 100 m (slm) 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 –
general note the technical data are subject to modification by the manufacturer › data sheets for different environmental/altitude 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
_ conditions are available on request requires only a valve clearance check at 2000 h.
the technical data sheets are available on request for gas of different composition (BIOGAS from ORGANIC FRACTION OF URBAN SOLID WASTE, —
BIOGAS from LANDFILL, other gases). Different gas are subject to verification of MWM Technical Department. general note the heat recovery data shown are to be confirmed during engineering stage
general note the technical data are subject to modification by the manufacturer
16 INTERGEN / COGENERATION 17

Control and monitoring Production plant

systems and test benches

Command and control panels, panels for medium voltage connection and monitoring Out of a total surface area of over 33000 m2, Intergen has a covered production space of 9000 m2 and an area
systems. Intergen completes its supply of cogeneration plants with the development of 8000 m2 used for external assembly and tests. The plant disposes of:
and construction of command, control and power panels designed upon customers’ specific
requirements, both hardware and software. Same engineering for the PLC software, plant › 2 soundproof test rooms › 1 soundproof test room › 2 mobile resistive benches
monitoring graphics and the HMI interfaces. for testing units for testing 3 units for power tests up to 6 MWe
up to 5 MWe each for a total power of 2 MWe
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.

› 1 fixed resistive bench › 3 6-axle trucks › 1 6-axle truck

for power tests up to 2 MWe for transport and handling for transport and handling
of 80 t load of 40 t load
development for: remote
› PLC software functions:
› monitoring graphics › via modem › 2 mobile tanks, 6 m3, The production facility has 2 overhead travelling cranes 30 t each,
› HMI interfaces › cable interface complete with instruments for handling purposes. The current production capacity allows more
for consumption tests than 80 units to be built and tested per year.
18 INTERGEN / COGENERATION 19

Who has chosen 1700+ MWe installed 260+ plants 180+ service
Intergen worldwide installed
in Italy
contracts

cogeneration
FOOD PAPER FOOD CHEMICAL PHARMACEUTICAL CHEMICAL
INDUSTRY MILL INDUSTRY INDUSTRY INDUSTRY INDUSTRY

2 x 1200 kWe, 2 x 600 kWe 2 x 4300 kWe, 1 x 3200 kWe 1 x 2000 kWe 1 x 1560 kWe 1 x 1200 kWe 1 x 1200 kWe

HOSPITAL HOSPITAL CARTIERA PAPER DATA CENTER BUILDING MATERIALS CERAMIC/

PONTEDORO MILL PRODUCTION BUILDING
INDUSTRY INDUSTRY

3 x 3900 kWe 4 x 3900 kWe 1 x 2000 kWe 1 x 1200 kWe 1 x 1560 kWe 1 x 2000 kWe

PAPER FOOD CHEMICAL TEXTILE CERAMIC/ WOOD

MILL INDUSTRY INDUSTRY INDUSTRY BUILDING
INDUSTRY

1 x 3200 kWe, 1 x 1200 kWe 1 x 800 kWe 1 x 600 kWe 1 x 1560 kWe 1 x 4300 kWe 1 x 1200 kWe
 THE ENERGY GENERATION

headquarters
via Garçia Lorca, 25
I-23871 Lomagna (LC)

sales department
ph: +39 039 5914800

service & maintenance

ph: +39 039 5914435

administration
ph: +39 039 5914469

2000/6 IGE 06/17

www.intergen.it
info@intergen.it