THE ENERGY GENERATION - Intergen€¦ · 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

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

[email protected]

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


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


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



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


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



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


container, Transformer

2 Waste and fresh

oil storage system

—

Intergen painting: RAL 7032 Pebble grey


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 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


Cogenerator range with MWM motors


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


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

[email protected]

THE ENERGY GENERATION - Intergen€¦ · 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

Documents