THE ENERGY GENERATION

Transcription

1 THE ENERGY GENERATION Cogeneration

2 2 intergen / cogeneration GROUP STRUCTURE Intergen, a long history Business Units Companies IML Motori srl (Italy) BU engines IML Motoare srl (Romania) IML Service srl (Italy) BU power plants IML Impianti srl (Italy) Intergen has been operating in the energy market for almost 0 years. The Hotel Gallia in Milan was one of its first customers, purchasing a generating set in 95. Intergen has also been designing and building cogeneration and trigeneration plants for prestigious customers for 25 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. Sales Divisions IML Motori industrial engines IML Power marine engines IML Crosstek components Intergen cogeneration Intergen generating sets & power plants installed power + MWe years of history 0 years sole distributor in Italy for since 98 gas units range from 00 to 00 kwe After Sales Service Italian market Service Worldwide Mission vision and values IML GROUP AT A GLANCE turnover 00+ mln euros people 60+ employees customers 000+ all over the world industrial area,000 square meters Since 200 Intergen holds quality certification: ISO 900:2008 ISO :200 We are members of: 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.

3 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 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: 0 in-house engineers 2/ response availability spare parts remote control of the plant hot water and/or steam for residential or industrial applications; refrigerated water by means of absorbtion type chillers. 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. know-how One of the few Italian companies to have a structured organization with a team of 0 in-house engineers. availability We can intervene promptly, 2 hours a day, 65 days a year, throughout Italy. capillarity The central warehouse guarantees shipment of spare parts to the decentralized storerooms at the plants within 2 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..5% electrical energy 0+% 8+% savings in primary energy total efficiency energy introduced by the fuel 00% cogeneration plant Energy efficiency.0% losses.5% thermal energy Using a cogeneration plant for industrial or residential applications results in savings in raw energy up to 0% 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 8%; this translates into higher cost savings, thus guaranteeing a fast return on investment. Intergen offers a maintenance service for both engines and plants through an internal structure which can provide the service 2 hours a day, 65 days a year. Intergen currently manages the maintenance of more than 80 plants, thanks to 0 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. services offered st level programmed maintenance 2 nd level programmed full service value VALORE of DEL the SERVIZIO service service SERVIZIO quality QUALITÀ - 20 fully-equipped vans - emergency response 2/ - spare parts within 2 hours

4 6 intergen / cogeneration 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. 00 kwe cogeneration plant prefabricated sound proof enclosure 560 kwe cogeneration plant prefabricated sound proof enclosure Segregated transformer room 0 Fluid circulation skid complete with pumps, Command & control room Medium voltage switchgear room heat exchangers and regulation system Compressed air motor starting system Ancillary panels (neutral point resistor, 2 Oxidizer catalyst 8 control unit, MWM TEM engine control panel) Exhaust gas line and silencer 5 Air intake section Walkways and radiator and catalyst area access Air expulsion section fitted with ATEX fans MWM engine-alternator unit 8 Access and maintenance platform 5 Emergency air cooler 6 Sound proof enclosure with access and removable panels for unscheduled maintenance activities 9 Radiator connection piping and fluid circulation skid

5 8 intergen / cogeneration 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 kwe cogeneration plant in container 560 kwe cogeneration plant in container Cogenerator and accessory container Waste and fresh oil storage system 6 2 Electrical container (command and control board / transformer / medium voltage) Emergency air coolers Silencers 5 Heat recovery boiler 8 Fluid circulation skid complete with pumps, heat exchangers and regulation system 9 SCR system (selective catalytic reactor) for NO X / CO reduction 0 Command and control panel room 6 Walkways and access to boiler and radiator area Transformer (low voltage/medium voltage) 2 2 Medium voltage switch gear

6 0 intergen / cogeneration 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.) kwe trigeneration plant in a building kwe cogeneration plant in a building 8 5 Cogeneration plant 2 Absorption chiller unit Silenced cooling tower Refrigeration unit/cooling tower water pumps skid 5 Fresh and waste oil storage system 6 Sound proofed air intake and expulsion ducts Fluid circulation skid complete with pumps, heat exchangers and regulation system 8 Emergency air coolers

7 2 intergen / cogeneration BIOGAS Cogenerator range with MWM motors NATURAL GAS PERFORMANCE () TCG206 TCG2020 TCG202 VO8 C V2 C V6 C V2 V2 V6 V20 V2 V6 electrical power COP according to ISO electrical efficiency thermal efficiency total efficiency Nm /h , 5, 8,5.,9 6,0 8, , 5,5 8, ,8,2 8, ,6, 86, ,2,8 8,0.5,,2 86, ,6 2,9 86, ,8,0 86,8 PERFORMANCE () TCG206 TCG2020 HEAT RECOVERY electrical power COP according to ISO VO8 C VO8 C V2 C V6 C V2 V2 V6 V engine jacket water and lube oil circuit heat intercooler circuit heat (2, 9) (2, 6) electrical efficiency thermal efficiency total efficiency Nm /h 2 0,, 8,8 0,0 8,2 25 2,,2 8,,2 8, 8, 2,8 8,9 509,6 2, 8,0 69, 2,5 8,8 85 2,5,8 8, exhaust heat after heat exchanger saturated steam flow rate, 8 bar cold water production (from jacket water and lube oil circuit heat) (2, 5) () (8) [kg/h] KWf HEAT RECOVERY engine jacket water and lube oil circuit heat exhaust heat after heat exchanger (2) (2, 5) cold water production (from jacket water, lube oil and exhaust gas heat) EMISSIONS exhaust gas flow rate (wet) (8) KWf [kg/h] ON REQUEST.8 ON REQUEST 22. EMISSIONS exhaust gas flow (wet) exhaust gas temperature [kg/h] [ C] exhaust gas temperature NO X (5%O 2 ) CO (5%O 2 ) with catalytic oxidizer () [ C] NO X (5%O 2 ) () MOTOR / ALTERNATOR DATA CO (5%O 2 ) with catalytic oxidizer configuration / no. of cylinders V08 V2 V6 V2 V2 V6 V20 V2 V6 MOTOR / ALTERNATOR DATA configuration / no. of cylinders speed rpm V08 V08 V2 V6 V2 V2 V6 V20 speed lube oil consumption starting system alternator voltage (0,, 2) rpm g/kwh V (+/- 0%) Electrical.000 0, 6, KV Pneumatic.000 0, 6, KV lube oil consumption starting system g/kwh Electrical Marelli alternator model MJB 55 MJB LC MJB MJB MJB MJB LA MJB 560 LB MJH 800 MB6 MJH 800 MC6 alternator voltage Marelli alternator model V (+/- 0%) MJB 55 MJB 55 MJB LC MJB MJB MJB MJB LA MJB 560 LB genset dry weight genset footprint [L x P] genset height [H] [kg] [m] [m] 5.0,x,6.000,x,6 8.,2x,6.00,8x,8.00,8x,8.20 5,5x, ,2x,.00,9x2,6, ,x2,6, genset dry weight genset dimensions [L x P] genset height dimensions [H] [kg] [m] [m] 5.0,x,6 5.0,x,6.000,x,6 8.,2x,6.00,8x,8.00,8x,8.20 5,5x, ,2x, MAINTENANCE maintenance interval hours before major overhaul (TBO) h h () () () REFERENCE CONDITIONS data valid for biogas with 55% CH (data sheets available for biogas 65% CH ) methane number: PCI: 5.6 kwh/nm combustion air temperature: 25 C combustion air humidity: 60% installation altitude: 00 m asl data sheets for different environmental / altitude conditions are available on request NOTES the 250 and NO X versions are available 2 heat power data are subject to a tolerance of +/- 8% data are subject to a tolerance of +5% data referred to 00% load (data for partial loads are available in the official data sheets) 5 exhaust heat after heat exchanger with cooling to 20 C. _ 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 _ 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. REFERENCE CONDITIONS methane number: 80 PCI: 0 kwh/nm combustion air temperature: 25 C combustion air humidity: 60% installation altitude:00 m (slm) data sheets for different environmental / altitude conditions are available on request NOTES the 250 NO X version is available 2 heat power data are subject to a tolerance of +/- 8% data are subject to a tolerance of +5% data referred to 00% load (data for partial loads are available) 5 exhaust heat after heat exchanger with cooling to 20 C 6 heat power with water/glycol solution at 5% steam production at 8 barg with economizer and water feeding at 80 C 8 data for the production of cold water at -2 C with COP= for the 202 series, the water/oil exchanger is not supplied assembled on the motor 0 for the 202 series, kv alternators are also available medium voltage alternators are available on request for the 2020 series 2 data for 50 Hz alternators, 60 Hz also available on request the 202V2 cogenerator calibrated at 250 mg/nm of NO X is rated to 20 Kwe electrical power the maintenance plan for the 206 motor requires only a valve clearance check at 2000 h. 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

8 intergen / cogeneration 5 Cogenerator range with Liebherr motors BIOGAS NATURAL GAS PERFORMANCE () PERFORMANCE () G9 G9 G96 G96 G9508 G9 G9 G96 G96 G9508 electrical power COP according to ISO electrical power COP according to ISO mechanical power at the motor shaft ICN [ISO 06-] mechanical power at the motor shaft ICN [ISO 06-] KW KW kg/h 0,0 8,0 06,0 2,0 68,0 kg/h 26,0 29,0 9,0,0 62,0 electrical efficiency 8,%,9%,8%,9% 8,2% electrical efficiency 8,8% 8,% 8,9% 8,9% 9,2% thermal efficiency,6%,6%,%,2%,% thermal efficiency,%,2%,%,%,% total efficiency 8,% 8,5% 80,9% 8,% 8,% total efficiency 8,% 82,6% 8,2% 8,% 8,5% HEAT RECOVERY HEAT RECOVERY engine jacket water and lube oil circuit heat (2, 6) engine jacket water and lube oil circuit heat (2, 6) exhaust heat after heat exchanger (2, 5) exhaust heat after heat exchanger (2, 5) total heat power (2) total heat thermal power (2) EMISSIONS EMISSIONS exhaust gas flow (wet) [kg/h] exhaust gas flow (wet) [kg/h] exhaust gas temperature [ C] exhaust gas temperature [ C] NO X (5%O 2 ) () NO X (5%O 2 ) () CO (5%O 2 ) with catalytic oxidizer CO (5%O 2 ) with catalytic oxidizer MOTOR DATA MOTOR DATA configuration / no. of cylinders L L L6 L6 V08 configuration / no. of cylinders L L L6 L6 V08 speed rpm speed rpm lube oil consumption g/h lube oil consumption g/h starting system Electrical starting system Electrical REFERENCE CONDITIONS data valid for biogas with 50% CH PCI: 5.0 kwh/nm combustion air temperature: 25 C combustion air humidity: 0% installation altitude: 00 m asl NOTES the 250 NO X version is available 2 heat power data are subject to a tolerance of +/- % data are subject to a tolerance of +5% performance referred to 00% load (data for partial loads are available in the official data sheets) 5 exhaust heat after heat exchanger with cooling at 20 C 6 heat power with water/glycol solution at 50%. _ general note the heat recovery data shown are to be confirmed during enigineering stage general note the technical data are subject to modification by the manufacturer REFERENCE CONDITIONS methane number: 80 PCI: 9.8 kwh/nm combustion air temperature: 25 C combustion air humidity: 0% installation altitude: 00 m asl NOTES the 250 NO X version is available 2 heat power data subject to a tolerance of +/- % data are subject to a tolerance of +5% performance referred to 00% load (data for partial loads are available in the official data sheets) 5 exhaust heat after heat exchanger with cooling to 20 C 6 heat power with water/glycol solution at 50%. _ 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

9 6 intergen / cogeneration Control and monitoring systems Production plant and test benches 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. Out of a total surface area of over 000 m 2, Intergen has a covered production space of 9000 m 2 and an area of 8000 m 2 used for external assembly and tests. The plant disposes of: 2 soundproof test rooms for testing units up to 5 MWe each soundproof test room for testing units for a total power of 2 MWe 2 mobile resistive benches for power tests up to 6 MWe development for: PLC software monitoring graphics HMI interfaces remote functions: via modem cable interface fixed resistive bench for power tests up to 2 MWe 2 mobile tanks, 6 m, complete with instruments for consumption tests 6-axle trucks for transport and handling of 80 t load 6-axle truck for transport and handling of 0 t load The production facility has 2 overhead travelling cranes 0 t each, for handling purposes. The current production capacity allows more than 80 units to be built and tested per year.

10 8 intergen / cogeneration 9 References Plants built by region Main plants built Intergen authorized network IML authorized network Company headquarters Cogeneration for ceramics industry, Modena 2 plants built with engine each, 00 kwe. Production of hot water and direct use of the fumes in the process. Cogeneration with biogas engine, Pavia Plant built with engine, 999 kwe. Production of hot water recovered from both the cylinder jackets and the fumes. 5 Cogeneration in hospitals, Milan 9 2 plants built with and engines, 00 kwe each, respectively. Production of steam and hot water for heating / air conditioning use. 6 Cogeneration with biogas engine, Ferrara Plant built with engine, 999 kwe. Production of hot water recovered from the cylinder jackets. 0 Cogeneration for paper industry, Lucca Plant built with engine, 560 kwe. Production of hot water and steam. Cogeneration for plastics industry, Sondrio Plant built with engine, 2000 kwe. Production of hot water and direct use of the fumes in the process. 8 0 Cogeneration for food industry, Monza Brianza Plant built with 2 engines, 2,000 kwe each. Production of steam and hot water. Cogeneration for engineering industry, Vicenza Plant built with engine,560 kwe. Production of steam and hot water. 8 Cogeneration serving a remote heating network, Rome Plant built with engine, 999 kwe. Production of hot water recovered from the cylinder jackets. Trigeneration for chemical/pharmaceutical industry, Bergamo Plant built with engine, 200 kwe. Production of hot water, cold water and steam. 2 Cogeneration for building materials production industry, Pisa Plant built with engine, 560 kwe. Production of hot water and direct use of the fumes in the drying process. Cogeneration for textile industry, Vercelli Plant built with engine, 560 kwe. Production of hot water and steam MWe installed 200+ plants 80+ service 0 years 98 worldwide installed in Italy contracts of history since sole distributor in Italy for

11 THE ENERGY GENERATION headquarters via Garçia Lorca, 25 I-28 Lomagna (LC) sales department ph: service & maintenance ph: administration ph: / IGE 0/6