AB | Case History
AB FOR AMADORI
Cogeneration in an integrated energy efficiency plan for the food sector
AB FOR AMADORI
AB is Amadori’s partner both for the plants in power stations powered with natural gas AND FOR the modular biogas plants.
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cogeneRATION
5
RATION 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
The choice of cogeneration therefore
intensive nature of the sector,
corresponds to an entrepreneurial
cogeneration is the ideal solution
philosophy that greatly focuses at
for the food industry also because
the optimization of consumption,
it allows the supply chain waste
the operability of the supply chain
to be used to produce biogas. The
and at eco-sustainability. A further
decisions made by the Amadori in
testimony to how the most dynamic
the field of energy efficiency highlight
companies of the sector are looking
the advantages that cogeneration can
for solid solutions properly tested
offer very well, adding an element that
and immediately feasible to lower
makes the case history even more
their costs and improve their energy
significant: the integration of plants
efficiency.
powered with natural gas and biogas.
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6
Amador
passion, organization and technology.
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ori. With six sites fitted with state-of-
feed production to rearing, from
the-art technology, the Amadori
incubators to food processing sites
is
industrial
and distribution, Amadori certifies
companies in the poultry sector:
the quality of processes and products
it combines a focus on Made in
to offer quality, safety and taste on
Italy quality with an organizational
the market. In particular, the food
vision of European scale. Amadori
processing
employs more than 7000 people of
by the public authorities in charge
80 different nationalities. It proposes
and certified ISO 9001, host various
around 1700 references and over
types of production lines of both
500 products. The company directly
traditional and innovative products.
manages
The
one
of
the
the
main
entire
integrated
basic
sites,
all
ingredients
recognized
of
each
supply chain: in this way it can
process are the passion for Italian
guarantee the origin of all the raw
food tradition and the awareness of
material and control on each stage
modern food demand which allow
of the production cycle, also thanks
specialities to be created able to
to an internal traceability system.
satisfy the requirements of even the
Involved in every stage from animal
most demanding consumers.
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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.
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Campese Amadori: range chicken.
inability.
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The energy efficiency needs of the
Mosciano Sant’Angelo
SITE
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TE
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A first important intervention of structural innovation
the biogas obtained by anaerobic digestion of fats
carried out by the Amadori in the field of energy
and proteins as well as breadcrumbs waste, which
efficiency was directed at the factory located in
contains oil and bread left over from the deep fryer.
Mosciano Sant’Angelo, in the province of Teramo.
Around 16,000 kilograms of organic load feed the
Here a cogeneration Ecomax BIO plant designed
digester each day. Via the EcomaxÂŽBIO plant thermal
and produced by AB has been installed with the
energy is obtained and fully used inside the site along
aim to enhance the biomass originating from the
with electrical energy, which is entirely injected into
supply chain waste. The plant is in fact fuelled with
the grid.
ÂŽ
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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.
THE
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Ecomax速 6 BIO Power
biogas
Biogas flow rate
Nm3/h
313
Electric power produced
kWe
625
Total electrical efficiency
%
40
from engine cooling water
kW
381
from exhaust gas fumes
kW
381
Thermal power produced:
Ecomax PLANT
速
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The energy hub at Amadori’s
Cesena
SITE ≤
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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.
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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 CO2 not emitted into the atmosphere, which is equal to a PES (Primary Energy Saving) above 20%.
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AB technologies powered with natural gas at the Cesena energy hub
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Biocogeneration in the Cesena energy hub
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Ecomax® 11 BIO Power
biogas
Biogas flow rate
Nm3/h
540
Electric power produced
kWe
999
from engine cooling water
kW
578
from exhaust gas fumes
kW
74
Thermal power produced:
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 CO2 not emitted into the atmosphere.
Layout Ecomax® 11 BIO
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The plant in the Amadori testimony. Interview with Lorenzo Battistini, Technical Manager Amadori
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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.
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AB SETS THE COGENERATION STANDARDS GLOBALLY 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
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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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