Cogeneration units are integrated energy systems that simultaneously generate electricity and useful heat within a single technological process. These solutions are used at facilities where on-site power generation, efficient use of the heat generated and reduced dependence on external energy supplies are important.
Unlike a conventional boiler plant, a cogeneration unit not only supplies heat for space heating, domestic hot water or industrial processes but can also meet part or all of the facility’s electricity demand, depending on its capacity and operating mode.
Cogeneration is most suitable for facilities with simultaneous and consistent demand for electricity and heat, where energy efficiency, reliability and operational flexibility are essential.
Depending on the facility’s requirements, a cogeneration unit can be stationary, free-standing, modular or containerised.
The equipment configuration is selected individually, taking into account the electrical and thermal loads, fuel type, operating mode, grid synchronisation requirements, automation and potential future expansion of the facility.
The most widely used cogeneration technologies include gas-engine, gas-turbine and steam-turbine units. The specific technology and configuration are selected according to the facility’s parameters, available fuel and the required ratio of electrical to thermal output.
Cogeneration units are an effective solution for facilities that require both electricity and heat.
By producing both forms of energy simultaneously within a single process, these systems use fuel more efficiently, reduce energy losses and improve the overall efficiency of the facility’s energy supply.
A cogeneration unit generates electricity and heat within a single technological process.
This is especially appropriate for facilities with constant or predictable electrical and thermal loads.
Cogeneration makes productive use of heat that is often lost in conventional generation systems.
This improves the overall efficiency of the energy system.
On-site generation of electricity and heat improves the facility’s operational reliability and provides greater control over energy consumption.
This is especially important for industrial, commercial and infrastructure facilities.
Cogeneration units can be gas-engine, gas-turbine or steam-turbine, as well as modular or containerised.
This makes it possible to select a solution based on the load, available installation space and project timescale.
Depending on the technology and technical specification, cogeneration units can operate on natural gas, biogas and other gaseous fuels.
This allows the solution to be adapted to the specific conditions of the facility.
Cogeneration is used at manufacturing facilities, hospitals, hotels, business centres, campuses, biogas facilities and energy centres.
Such systems work best where electricity and heat are consumed simultaneously.
Cogeneration units are suitable for facilities with simultaneous and reasonably stable demand for electricity and heat. The combination of these two loads is one of the main factors in the efficient operation of a cogeneration unit. The specific siting and connection configuration is determined individually, taking into account the building type, fuel type, operating mode, grid-connection requirements and applicable regulations.
Food and Processing Industries
Hotels and Apartment Complexes
Hospitals and Medical Complexes
Manufacturing Enterprises
Office Centres and Multifunctional Complexes
University Campuses and Large Facilities with District Heating
Agricultural and Biogas Complexes
Wastewater Treatment Plants and Other Infrastructure Facilities
Facilities Requiring Electricity, Heat or Process Steam
Energy Centres and District Heating Systems
The most common option for modular, medium-capacity cogeneration solutions. It is well suited to facilities with stable electricity and heat demand where flexibility, modularity and relatively rapid commissioning are important.
Suitable for higher-capacity applications where electricity and a significant amount of heat need to be generated simultaneously. Such units are commonly used at industrial facilities, energy centres and large engineering complexes.
Used primarily at industrial facilities with boiler or steam-generating equipment, where high-pressure steam is first used to generate electricity in a steam turbine and then for process applications or heat supply. Such solutions are particularly effective at large facilities with consistent demand for steam and thermal energy.
Suitable for lower-capacity applications and specialised tasks where compactness, modular design and stable operation are important. Such solutions are well suited to selected commercial and infrastructure facilities.
Specialised units designed to generate electricity from low-grade or recovered heat, including heat produced by biomass combustion. They are suitable where a stable heat source with appropriate temperature parameters is available and their use is supported by a sound technical and economic assessment.
What Is Included in a Cogeneration UnitThe equipment scope depends on the unit type, capacity, fuel type, operating mode and technical specification. A basic cogeneration unit may include:
Where required, the solution may also include buffer tanks, absorption chillers for trigeneration, backup heat sources, automation panels, weather-compensated control systems and integration with the facility’s overall supervisory control system. |  |
01 Automatic control and protection systemReal-Time Parameter MonitoringContinuous monitoring of electrical and thermal parameters, as well as the operating parameters of the primary unit and auxiliary systems. Multi-level equipment protectionThe system can issue warnings and initiate automatic unloading or an emergency shutdown of the unit when key parameters exceed permissible limits. Fuel System and Combustion Parameter MonitoringThe design may include solutions for monitoring engine stability and compliance with environmental requirements. 02 Synchronisation and Load ControlSynchronisation with the Power GridThe control system ensures correct connection of the unit to the grid and controls grid-parallel operation. Operation in different modesDepending on its configuration, the unit can operate in parallel with the grid, in stand-alone mode or cover peak loads. Dynamic load controlThe automation system coordinates unit operation with the facility’s current demand for electricity and heat while maintaining the stability of the internal power network. 03 Monitoring and Supervisory ControlRemote monitoring and access to operating parametersSelected solutions can include web-based dashboards, remote access and remote service monitoring of the unit. Transmission of events and emergency messagesThe system can transmit alarms, warnings and operational notifications to a control room or service team. Archiving and analyticsStoring parameter and event histories simplifies efficiency analysis, equipment servicing and work planning. Predictive-maintenance functions are available for selected systems. Integration with BMS or SCADAThe cogeneration unit can be integrated with the facility’s overall supervisory control system. The specific protocols and integration method are defined by the design and the selected automation system. | A modern cogeneration unit is a highly automated energy system in which the control system maintains stable operating parameters, protects the equipment, synchronises the unit with the power grid and supports high fuel efficiency. The level of automation, remote access and analytics is determined by the configuration of the specific solution.  |
| Parameter | Configuration Options |
|---|---|
Thermal capacity
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Determined by the type of primary technology, unit configuration and heat recovery scheme. |
Fuel type
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Natural gas, biogas, liquefied petroleum gas (LPG) and other gaseous fuels — depending on the technical specification, fuel quality and equipment characteristics. Hydrogen blends are possible for certain solutions. |
Configuration
|
Stationary, block-modular or containerised. |
Operating modes
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Grid-parallel, stand-alone, backup or combined — depending on the system configuration and the facility’s requirements. |
Turnkey supply
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From the fuel system and primary unit to heat recovery systems, automation, metering units and flue gas extraction. |
Electrical output
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From small modular solutions to large-capacity industrial units; selected individually according to the facility's consumption profile. |
Heat-transfer fluid
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Hot water, a process heat-transfer medium or steam — depending on the purpose of the unit and the facility’s requirements. |
Electrical efficiency
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Depends on the unit type, capacity and load profile. |
Overall efficiency
|
With correct system selection and full utilisation of the thermal energy, cogeneration can provide high overall fuel efficiency; for many solutions, the reference range is approximately 65–80%, and for certain configurations it is up to 90%. |
Noise level
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Determined by the unit type, capacity and configuration. Acoustic enclosures or a containerised configuration are provided where required. |
Service life and maintenance intervals
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Depend on the type of unit, manufacturer, operating mode and maintenance schedule. |
Environmental performance
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Determined by the technology, fuel type, emissions-control system and emission requirements for the specific facility. |
Digital infrastructure
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Remote monitoring, parameter archiving and integration with the facility’s supervisory control system — depending on the level of automation. |
We provide more than equipment supply: we deliver a comprehensive engineering solution from initial engineering through to commissioning.
Each cogeneration unit is configured individually, taking into account the electricity and heat consumption profile, fuel type, operating mode, the facility’s engineering infrastructure, synchronisation and automation requirements, and the system’s future development.
Site-specific system selection
Complete turnkey project delivery
Modern energy-efficient equipment
Automation, synchronisation and supervisory control
Modular and containerised solutions
Installation, Commissioning and After-sales Service
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Cogeneration is the simultaneous production of electricity and useful heat in a single process. A cogeneration unit is equipment that provides this combined output or recovers usable energy that would otherwise be wasted.
An engine or turbine drives a generator, while heat from the exhaust and cooling system is recovered for space heating, domestic hot water, steam or process use. Other cycles may be specified in the design.
A typical system includes an engine or turbine, generator, fuel system, heat-recovery equipment, cooling and exhaust systems, pumps, controls and safeguards, grid-synchronisation equipment, electrical switchgear, metering and acoustic attenuation.
Neither is universally better. Gas-engine units are generally better suited to smaller and variable loads, while gas turbines suit extended operation and applications requiring higher-temperature heat. The choice should be confirmed by a techno-economic assessment.
A 100 kW unit is suitable where there is sustained, simultaneous demand for electricity and the recovered heat. It should be sized using hourly annual consumption profiles, the site’s minimum load and connection requirements—not the peak demand alone.
Natural gas, treated biogas, biomethane, liquefied petroleum gas (LPG) and other fuels approved by the manufacturer for the specific technology. Recoverable waste-energy potential may also be used.
A high-efficiency unit achieves primary-energy savings of at least 10% for units other than small-scale or micro units, and more than 0% for small-scale and micro units. A qualified unit is one that has voluntarily completed the free qualification procedure administered by the State Agency on Energy Efficiency and Energy Saving of Ukraine.
No separate licence is required merely to operate the cogeneration unit. Depending on the project, documentation may be required for construction and commissioning, grid connection, emissions and high-risk equipment. A licence may be required to generate or sell electricity or heat; it is generally not required for self-supply.
The main factors are electrical and thermal output, technology, fuel, heat-recovery scope, connection requirements, controls, acoustic attenuation and civil works. A quotation requires hourly consumption profiles and data on the fuel supply, utility networks and site.
Where electricity and heat are needed concurrently and consistently, payback depends on fuel and grid-electricity prices, the proportion of recovered heat used, efficiency, service and connection costs, financing terms and revenue from energy sales.
Industrial cogeneration units produce electricity and useful heat simultaneously within a single energy complex. The recovered thermal energy can be used for space heating, domestic hot water or industrial processes. Cogeneration is most suitable for facilities with a stable, simultaneous demand for electricity and heat. The configuration is selected according to the operating profile of each facility. Teploformat Engineering provides cogeneration unit design, equipment supply, installation, connection and commissioning.
In a gas-engine or gas-turbine cogeneration unit, the engine or turbine drives a generator to produce electricity. Heat from the cooling system and exhaust gases is not wasted: a heat recovery system captures it and transfers it to consumers through heat exchangers.
The recovered heat can be used for heating, domestic hot water, process water heating or steam generation. Automation coordinates electrical and thermal loads, controls auxiliary equipment and synchronises the unit with the power grid.
Electrical, thermal and overall efficiency depend on the technology, unit capacity, operating mode and actual utilisation of the recovered heat.
A high level of electricity consumption alone does not justify a CHP project. The electrical and thermal loads must also occur at the same time. Industrial cogeneration units can be suitable for manufacturing facilities, agricultural and biogas complexes, greenhouses, hospitals, hotels, shopping centres, water utilities, wastewater treatment plants and district heating systems.
Important conditions include a stable base load, a high number of annual operating hours, predictable fuel availability and the ability to use heat outside the heating season. High electricity prices, limited reliability of the external power supply, a demand for process hot water or steam, and access to biogas may provide additional justification.
If a substantial amount of recovered heat must regularly be rejected into the atmosphere, the economic performance of the cogeneration project will decline.
A cogeneration unit should not be selected only according to the facility’s maximum electrical demand. The engineering assessment should consider the hourly electricity consumption profile, daily and seasonal heat demand, minimum base load, peak values, required heat-transfer fluid temperature and demand for process steam.
Other factors include acceptable operation at partial load, the ability to export electricity or the need to restrict export, as well as planned facility expansion.
In many cases, it is more practical to size the unit according to the base electrical or thermal load. This enables it to operate for a sufficient number of hours without frequent shutdowns while the generated energy is consumed directly on site.
A gas-fired cogeneration unit most commonly operates on natural gas with stable characteristics. A broad range of gas-engine and gas-turbine equipment is available for this fuel. Where necessary, the heat source can be combined with a gas-fired boiler plant to cover peak loads.
A biogas cogeneration unit may be suitable for agricultural enterprises, landfills and wastewater treatment facilities. Before selecting the equipment, the gas composition must be analysed and an appropriate treatment system designed. This may include controlling moisture, hydrogen sulphide, siloxanes and other impurities.
Biomethane, LPG and other gaseous fuels may only be used after the equipment manufacturer has confirmed compatibility. Fuel composition, calorific value and knock resistance must meet the manufacturer’s requirements.
Gas-engine cogeneration units are widely used in the small and medium capacity ranges. They support modular expansion and can operate relatively flexibly under changing loads, making them suitable for many industrial and commercial facilities.
Gas-turbine units are generally considered for higher capacities and systems requiring a substantial amount of high-temperature heat. They are frequently used in energy centres and large industrial systems.
The choice of technology depends not only on electrical capacity but also on the required heat parameters, available fuel, operating schedule, site conditions and maintenance requirements.
During grid-parallel operation, the cogeneration unit is synchronised with the external power grid and covers part or all of the facility’s current electricity demand. If electricity export is not permitted, the control system prevents or limits surplus electricity from being fed into the grid in accordance with the approved connection arrangement.
In island mode, the cogeneration unit supplies a dedicated internal network. In backup operation, it can support specified critical loads. However, not every cogeneration unit will automatically continue operating if the external grid fails.
This functionality requires island-mode capability, suitable protection systems, automatic grid separation and sufficient ability to accept variable loads. In some cases, black-start capability is also required. The applicable grid connection and operating requirements must be determined separately for each project.
Recovered heat can be used for space heating, domestic hot water, drying, raw material preheating, maintaining process temperatures, steam generation or supplying heat to neighbouring facilities.
The thermal system may include heat exchangers, buffer tanks, emergency cooling equipment and multi-fuel boiler plants for backup and peak-load coverage.
Trigeneration supplements the production of electricity and heat by producing cooling through an absorption chiller. This solution may be suitable for food-processing plants, cold-storage facilities, hospitals, hotels, shopping centres and buildings with substantial summer cooling demand.
Trigeneration makes it possible to use recovered heat during periods when space-heating demand is lower, helping maintain a more consistent thermal load throughout the year.
The economic result depends on the cost and reliability of fuel supply, the price of electricity displaced by on-site generation, the amount of heat used beneficially, annual operating hours and the unit’s actual load profile.
The assessment must also include maintenance costs, operating hours before major overhaul, grid connection expenses, backup equipment, taxes, applicable charges and total capital expenditure.
For this reason, the payback period can only be determined after an individual technical and economic assessment and comparison of suitable configurations. Examples of completed engineering projects are available in the Teploformat Engineering portfolio.
The control system monitors the engine or turbine, fuel supply, electrical load, thermal circuit and grid synchronisation. It can provide emergency load shedding or shutdown, alarm notifications, operating data storage and remote monitoring. Integration with a building management system or SCADA can also be provided where required.
The project must also address ventilation, exhaust gas removal, noise, vibration, fire safety and environmental requirements. Scheduled maintenance is planned according to the manufacturer’s recommendations and actual operating conditions. Further information about technical support is available in the Warranty and Service section.
When designing cogeneration units in Ukraine, Teploformat Engineering collects the required input data and analyses electrical and thermal load profiles together with the characteristics of the available fuel. The engineers develop an energy balance, conduct a technical and economic comparison, and select the appropriate technology, electrical capacity and thermal output.
Teploformat Engineering designs the thermal and electrical systems, supplies the equipment, performs cogeneration unit installation, and handles connection and grid synchronisation.
The scope of work also includes commissioning, automation configuration, personnel training and service support. A modular cogeneration unit is adapted to the site, existing utility networks and required operating mode.
For a preliminary assessment, provide hourly or monthly electricity and heat consumption data, information about the available fuel, thermal system parameters and the required mode of operation with the power grid.
Complete the preliminary assessment form, and the Teploformat Engineering team will prepare an energy balance and propose a technically justified configuration.
