Service of gas power generators

Cogeneration

Agregaty S.A. has been assembling and providing maintenance of Cogeneration Systems for over 10 years.

Based on knowledge and experience gained while conducting previous projects, we have designed a cogeneration system – as universal, as optimal for a given application.

We offer full service including installation, the commissioning and regular maintenance and preventive maintenance.

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CHP (Combined Heat and Power) – electricity and heat

Cogeneration systems simultaneously generate in one process heat and electricity. As a result, we are able to achieve an overall system efficiency of up to 90%.

The electricity generated is either used for a facility’s thermal requirements or is transferred to the public power grid, to cover some heating and electricity demand.

Thermal energy can be used both for the production of heating water and steam, and for the production of many types of process heat. It can also be used for ice water production.

How is the heat recovered while the engine is running?

The operation of an internal combustion engine involves constant heat production. In traditional systems, this heat is directed to a radiator and is discharged into the air, which significantly reduces the efficiency of the entire system. Recovering heat and collecting it from the engine can be conducted through various heat recovery technologies. In the cogeneration systems, the combustion engine exhaust energy can be used in any way we wish. It depends on the needs of the local facility (e.g. to produce heating water and steam, or to generate various types of process heat).

The engine - the "heart" of cogeneration

In our cogeneration system, we use engines made by German Company MTU, belonging to the Rolls-Royce group. The MTU 4000 series, specially developed for gas generators, is of the highest quality, reliability, and known for its high engine performance. We use engines in V8/V12/V16/V20 systems with electrical power from 776 kW to 2535 kW.

Cogeneration – TECHNOLOGY, Heat recovery system

We use heat recuperation systems that make full use of the heat energy generated (heat is captured directly from the engine, cooling systems and from the exhaust gases). On top of this, correctly setting system parameters allow us to maximise the benefits of the application.

The complete CHP system, we usually deliver to our customers, consists not only of the CHP module itself, which is placed in a soundproof container. It is also fitted with a range of equipment and installations necessary for the proper and safe operation of the unit.

The most essential are:

emergency cooling unit with fan cooler – for emergency heat collection
collection of process heat from the power generator – a system of exhaust heat exchangers, equipped with the necessary piping, fittings, circulation pumps and an automatic control system. It has been designed for thermal energy recovery from the cooling unit (lubricating oil, mixture cooling, engine block) and exhaust gases and for transferring it to the heating water system,
generator ventilation – ensures the required amount of air is supplied to the engine (air fan, temperature sensors, air acoustic silencers) and container interior is cooled;
gas path – consists of safety and regulation system for biogas pressure (filter, safety valve, solenoid valves, pressure sensors, zero pressure regulator)
gas detection system,
oil installation – installation with fresh oil tank, supplying the power generator with the required amount of oil (oil pump, oil pump control)
switch cabinet – checking the parameters of the power generator engine and its components, also the silencer for exhaust gases.

Control systems – process automation

High-quality components and precise control systems guarantee the highest operational efficiency and reliability. Modern, fully automated system.

ComAp – a powerful set of control and monitoring functionalities

Automatic sequence of starting, synchronisation and generator-to-grid coupling;
Active and reactive generated power adjustment;
Control of heat recovery systems;
Control of engine and generator performance;
Supervision, measurements, diagnostics and protection in case of disturbances or failures;
Advanced functionalities of data collection and presentation, charts, history of events, data export;
SCADA system – advanced functions of remote supervision and control.

Service, inspections, Diagnostics, repairs, upgrades

Our company offers a full service for CHP units, we undertake repair and overhaul work. Qualified and experienced technicians demonstrate a professional approach and are able to provide a wide range of mechanical, electrical and automation services such as diagnostics, repairs or CHP systems upgrading. For our customers, we provide consultant support and a 24/7 technical support line.

POLIgeneration – even more beneficial!

Expanding CHP units with additional installations allows us to optimise the use of a CHP-based application. The creation of tri-generation or even polygeneration solutions allows us to better adapt our products to the diverse needs of our customers.

TRI-GENERATION – CCHP (COMBINED COOLING HEAT AND POWER) – COLD, HEAT, AND ELECTRICITY.
In our climatic zone, for example, buildings are heated for about 6 months throughout the year. During the rest of the year, only hot water is utilised. In order to make use of the heat generated during operation, the system can be expanded with additional modules. By means of these devices, using heat collected from the operating CHP generator set, chilled water can be produced; which, then, can be used, for example, for air-conditioning rooms in office buildings, flats or public facilities.

STEAM GENERATOR

The CHP-system can be also expanded with a steam generator. This one is applicable for processes requiring higher temperatures, for example for saturated steam production with a temperature of around 200 °C.

CO2 – USE OF CARBON DIOXIDE CO2

The next possibility is to recover carbon dioxide from exhaust gases, and to use it in various technological processes – e.g. for the production of carbonated drinks. It can also be utilised in greenhouse farms, to supply proper CO2 dose to plants to ensure their optimal growth.