AB Case History. AB FOR AMADORI Cogeneration in an integrated energy efficiency plan for the food sector

Transcription

1 AB Case History AB FOR AMADORI Cogeneration in an integrated energy efficiency plan for the food sector

2 AB FOR AMADORI

3 AB is Amadori s partner both for the plants in power stations powered with natural gas AND FOR the modular biogas plants.

4 4 cogener

5 5 ATION IS STRATEGIC FOR THE FOOD SECTOR The supply chains of the food industry are highly energy intensive and use large quantities of steam, hot water and cold water. Considering the particular energy intensive nature of the sector, cogeneration is the ideal solution for the food industry also because it allows the supply chain waste to be used to produce biogas. The decisions made by the Amadori in the field of energy efficiency highlight the advantages that cogeneration can offer very well, adding an element that makes the case history even more significant: the integration of plants powered with natural gas and biogas. The choice of cogeneration therefore corresponds to an entrepreneurial philosophy that greatly focuses at the optimization of consumption, the operability of the supply chain and at eco-sustainability. A further testimony to how the most dynamic companies of the sector are looking for solid solutions properly tested and immediately feasible to lower their costs and improve their energy efficiency.

6 6 Amador passion, organization and technology.

7 7 i. With six sites fitted with state-ofthe-art technology, the Amadori is one of the main industrial companies in the poultry sector: it combines a focus on Made in Italy quality with an organizational vision of European scale. Amadori employs more than 7000 people of 80 different nationalities. It proposes around 1700 references and over 500 products. The company directly manages the entire integrated supply chain: in this way it can guarantee the origin of all the raw material and control on each stage of the production cycle, also thanks to an internal traceability system. Involved in every stage from animal feed production to rearing, from incubators to food processing sites and distribution, Amadori certifies the quality of processes and products to offer quality, safety and taste on the market. In particular, the food processing sites, all recognized by the public authorities in charge and certified ISO 9001, host various types of production lines of both traditional and innovative products. The basic ingredients of each process are the passion for Italian food tradition and the awareness of modern food demand which allow specialities to be created able to satisfy the requirements of even the most demanding consumers.

8 8 A strong commitment to eco-sustain At the Amadori s six Italian sites there is a large uses comes from renewable sources, according to emphasis on energy efficiency and the protection of a green economy philosophy that also includes the the environment. development of an energy efficiency plan which has In fact the Company has always been committed to cogeneration as its main applied technology. The fact developing in harmony with the area where its sites that the Amadori has chosen to aim at cogeneration are located, aiming at finding a balance between with AB is a further testimony of the large focus reduction of the consumption and the increase of reserved for this technology, which is integrated with energy efficiency. a general innovation plan dedicated to energy and In fact over 50% of the electrical energy that Amadori eco-sustainability.

9 9 Campese Amadori: range chicken. ability.

10 10 The energy efficiency needs of the Mosciano Sant Angelo SITE

11 11 A first important intervention of structural innovation carried out by the Amadori in the field of energy efficiency was directed at the factory located in Mosciano Sant Angelo, in the province of Teramo. Here a cogeneration Ecomax BIO plant designed and produced by AB has been installed with the aim to enhance the biomass originating from the supply chain waste. The plant is in fact fuelled with the biogas obtained by anaerobic digestion of fats and proteins as well as breadcrumbs waste, which contains oil and bread left over from the deep fryer. Around 16,000 kilograms of organic load feed the digester each day. Via the Ecomax BIO plant thermal energy is obtained and fully used inside the site along with electrical energy, which is entirely injected into the grid.

12 12 The modular cogeneration package plant Ecomax stands out as one of a kind thank to its design and production models and processes, which are the result of applied research and thirty years experience of AB. Ecomax is an industrial product based on principles of versatility, modularity, and compactness, and capable of combining these distinctive characteristics with high energy performance. An idea thought up and developed entirely at AB, which is the main technological and market reference point of modern cogeneration both in terms of product range and possibilities of application. Layout Ecomax 6 BIO Ecomax BIO is the plant design solution that applies the distinguishing features of this exclusive AB technology to the biogas power field. To meet the demands of Amadori s Mosciano Sant Angelo site, the AB specialists advised the installation of Ecomax 6 BIO in a configuration fine-tuned to the specific needs of the site so that they integrate perfectly with the already existing systems, in particular as regards the use flows of thermal energy. The system produces 14,800 kwh of electrical energy which completely injected into the grid and 16,000 kwh of thermal energy both from the recovery of the combustion fumes (10 bar steam) that all sent inside the site, and from the hot water of the engine, 50% of which is used for the needs of the production site and 50% for reheating the digesters.

13 13 Ecomax 6 BIO Power biogas Biogas flow rate Nm 3 /h 313 Electric power produced kwe 625 Total electrical efficiency % 40 Thermal power produced: from engine cooling water kw 381 from exhaust gas fumes kw 381 THE Ecomax PLANT

14 14 The energy hub at Amadori s Cesena SITE

15 The technological system includes a thermal power station integrated with two cogeneration plants powered with natural gas. This is combined with an anaerobic digester for exploitation of waste (biogas) deriving from the slaughtering process. 15

16 16 At Amadori s Cesena site a real energy hub has been realized which includes a thermal power station integrated with two cogeneration plants powered with natural gas, respectively of 3 and 4 MWe. The integration between the thermal power station and two cogenerators insures a very high performance and a better distribution of the heat vector. The three steam generators (boilers) in fact have a yield of 95% (usually yield does not exceed 92%); moreover the system uses a distribution method of the heat vector (hot water and steam) which was designed to use heat waste from the cogenerate as effectively as possible and limit energy waste. The high efficiency of the new hub allows a saving of around 3,600 TOE (Tonnes of Oil Equivalent) corresponding to around 10,000 tonnes/year of CO 2 not emitted into the atmosphere, which is equal to a PES (Primary Energy Saving) above 20%.

17 17 AB technologies powered with natural gas at the Cesena energy hub

18 18 Biocogeneration in the Cesena energy hub

19 19 Ecomax 11 BIO Power biogas Biogas flow rate Nm 3 /h 540 Electric power produced kwe 999 Thermal power produced: from engine cooling water kw 578 from exhaust gas fumes kw 74 At the Amadori s Cesena site an anaerobic digester has also been installed for processing the waste from the slaughtering process and allow to recover biogas from the cleaning cycle. The biodigestion system in fact treats the waste from the slaughtering process and thus obtain an amount of biogas sufficient to power a 1 MWe cogeneration plant, with the complete use of heat waste. In this way around 1500 TOE (Tonnes of Oil Equivalent) are saved corresponding to around 4000 tonnes/year of CO 2 not emitted into the atmosphere. Layout Ecomax 11 BIO

20 20 The plant in the Amadori testimony. Interview with Lorenzo Battistini, Technical Manager Amadori

21 21 What is your view on energy efficiency from cogeneration in the light of your experiences to date? Cogeneration is definitely one of the best technologies available today to maximise energy recovery, whatever the primary source used. In designing and sizing the cogeneration plants along with AB, Amadori has certainly applied the methodology that guarantees the maximum recovery of the thermal energy which the system inevitably produces while running. It is only with this approach that you can be sure of making the most of the possibilities that the cogeneration system allows. In the transformation of a primary energy source such as methane gas and even biogas, it is necessary to recover as much of the heat as possible - which otherwise would have been disposed of in another way - to guarantee the correct functioning of the system. How do you view the collaboration with AB, even in terms of respect of the planning and the service activities? AB is a partner who is easy to work with thanks to the professionalism of its operators. Amadori has chosen to collaborate with AB because its skills from a technical point of view and the planning ability of its professionals were immediately clear. However, the most important thing for us, with such complex plants like the ones which we have installed, is being able to count on an excellent after sales support. This is the only way to establish a strong partnership with the supplier, i.e. a relationship that is not exhausted in the installation of the plant, but which continues and is strengthened even after this, with constant checking of the achievement of the objectives established at the start of the project. Do you think that cogeneration and also BIO can be developed further in your energy efficiency plans? We believe that the systems that allow to make energy transformation efficient will always be a focal point of our company s technicians. On a daily basis the cogeneration systems improve their performances and therefore maintain a record in our view, both in financial and technical terms, which up to now has not been easily matched by others. We are determined to continue choosing systems that make it possible to use all the thermal energy that the system can produce. In our supply chain, the availability of matrices capable of producing high quality biogas from biodigestion only reinforces the choices of this type of technology for the combined production of heat and electric energy with considerable benefits both in financial and environmental terms.

22 22 AB SETS THE COGENERATION STANDARDS GLOBALLY AB industrial Group has been operating for over 30 years in the sector of cogeneration and promotion of energy from renewable sources. AB is currently made up of 24 companies and over 500 employees and is a single entity able to manage the entire manufacturing cycle of a cogeneration plant: consultancy, design, production, installation and start-up with a comprehensive service. This has enabled AB to acquire unparalleled know-how, to become acquainted with every product detail and to provide a top-quality and highly-effective aftersales service. The success of AB - which has already designed and built more than 900 plants - stems from ongoing investments in cutting-edge technologies, from the constant training and professional specialisation of all operators and from the development of an absolutely unique engineering department: a team of over 110 engineers engaged in developing the industry towards the production of increasingly more reliable and higher performance plants. AB cogeneration plants are distinguished by modularity, compactness and ease of transport and cater to the energy requirements of a number of different companies. Outright leader in Italy, AB is also expanding globally: in Spain (2007), in Romania (2009), in Poland (2010), and again with the opening of subsidiaries in Croatia and Serbia (2011). From 2012 AB is in Czech Republic, from 2013 also in the Netherlands, Austria, Brazil, Francia and Canada. From 2014 AB in UK, Germany, USA and Israel and from 2015 in Russia and Turkey too. ita ly SALES SpA Foreign Branches International GmbH España S.L. Romania Srl KWE Technika Energetyczna Sp. z.o.o. Hrvatska d.o.o. Srbija d.o.o. Ceská s.r.o. do Brasil Ltda Green House Power Netherlands BV EPS Canada Ltd. (UK) Ltd. Deutschland GmbH Russia Israel Ltd. USA Lcc AB HOLDING SPA PRODUCTION France AB Plants Srl Turkey AB Power Srl SERVICE AB Service Srl FINANCING AB Fin-solution SpA RENEWABLE ENERGY AB Ambiente Srl

23 Cogeneration has proven to be a winning choice, also in other industrial and non-industrial fields, such as food chemical, pharmaceutical, textile, plastic, paper, brick, etc. 700 customers, some of them are: Amadori, Benetton, BNL, Buitoni, Cartiere Saci, Coca - Cola, Cotonificio Albini, Eridania, Esselunga, Fatro, Ferrero, Felli Color, Galbani, Garda Plast, Granarolo, Gruppo Cremonini, Gruppo Mapei, kraft, Lafarge, Lilly, Martini & Rossi, Nestlè, Orogel, Pastificio Garofalo, Pastificio Rummo, Peroni, Pfizer, Polynt, Spumador, Wienerberger, etc.

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