What are cogeneration plants? Operating features of CHP and CCGT plants in Ukraine

Cogeneration units (CHP) and combined cycle gas turbine (CCGT) plants are modern sources of decentralized generation that allow for the simultaneous production of electrical and thermal energy with maximum utilization of the fuel's energy potential.

Unlike traditional power plants, where a significant portion of thermal energy is wasted, a cogeneration power plant utilizes the heat from exhaust gases, engine cooling systems, or gas turbines to support technological processes, heating, or hot water supply.

The efficiency of modern gas-piston cogeneration units can exceed 85-90%, making them one of the most effective solutions for industrial enterprises, district heating companies, critical infrastructure facilities, and centralized heat supply systems.

Under conditions of wartime risks and instability in the power grid, cogeneration units have become an important element of Ukraine's energy security, providing backup and primary power supply to consumers.

Technical features and specifications of CHP units

Design and operating principle of cogeneration plants (CHP)

The core of a cogeneration unit is a gas-piston or gas-turbine unit that drives an electrical generator. During operation, the unit generates electricity, while the thermal energy produced during the engine or turbine operation is recovered through heat exchange equipment (a waste heat recovery boiler) and used by the consumer.

Main structural elements of a cogeneration power plant

The standard configuration of an industrial cogeneration system includes the following components:

• gas-piston engine;
• electrical generator;
• heat recovery system;
• heat exchange equipment;
• gas supply system;
• cooling system;
• chimneys and gas ducts;
• automation systems and process control systems (PCS);
• transformer and distribution equipment;
• pumping stations and auxiliary engineering systems.

Combined cycle gas turbine plants additionally utilize the waste heat from gas turbine exhaust gases to produce steam and generate additional electricity via a steam turbine, allowing for even higher fuel efficiency.

Classification and types of cogeneration plants

Depending on the technology and purpose, cogeneration units are divided into:

• by compressor operating principle: gas-piston and gas-turbine;
• by type of fuel used: natural gas; biogas; liquefied petroleum gas (LPG / LNG).

LLC “Inventum Ukraine” has experience working with equipment from leading global manufacturers, including Jenbacher, MWM, Caterpillar, MAN, Siemens, GE, and others.

Benefits of combined heat and power for high-intensity businesses:

• increasing the energy independence of the enterprise;
• capability to operate in island (isolated) mode;
• fast commissioning;
• high coefficient of performance (efficiency);
• reduction of CO₂ emissions;
• capability of integration with existing heat supply systems;
• automated control and remote monitoring.

Due to the modular design principle, the capacity of cogeneration power plants can range from a few hundred kilowatts to tens of megawatts.

Integrated power solutions for industrial enterprises by Inventum Ukraine: cogeneration and combined cycle plants

The company performs a full range of works for the construction, reconstruction, and modernization of cogeneration units and combined cycle power complexes:

• engineering and development of design and estimate documentation;
• installation of gas-piston units;
• installation of gas turbine equipment;
• installation of steam turbines and generators;
• construction of foundations and buildings for energy facilities;
• installation of pipelines, gas ducts, and chimneys;
• installation of pumping and heat exchange equipment;
• installation of automation systems, instrumentation, and process control systems (PCS);
• fabrication and installation of steel structures;
• thermal insulation and anti-corrosion protection of equipment;
• construction of reinforced concrete protective structures;
• installation of anti-drone and pre-detonation metal structures;
• commissioning works;
• service and technical maintenance.

Inventum Ukraine: realized projects of decentralized generation and cogeneration

LLC “Inventum Ukraine” has practical experience in implementing decentralized generation and cogeneration projects across Ukraine.

Among the most significant projects:

• construction of a thermal energy generation facility with a capacity of 40 MW in the city of Okhtyrka;
• construction of an extension for main circulating pumps in the turbine department of a CHP plant, with the installation of a condensing steam turbine unit with a capacity of 25 MW;
• construction of five Jenbacher cogeneration units;
• reconstruction of boiler houses with the installation of cogeneration units for district heating enterprises;
• modernization of engineering systems for operation from cogeneration units at centralized heat supply facilities.

The implemented projects confirm the company's competence as an EPC contractor capable of executing the full cycle of works – from engineering to commissioning the facility into commercial operation.