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Florim

Cogeneration plant, Mordano (BO)
Power Generation
Customer Florim
Where Mordano (Bo)
Solution Power Generation | Cogeneration with turbine
Sector Industrial | Ceramic

During a period of considerable investment planned by Florim Ceramiche for the expansion of its Mordano plant, Cefla designed and installed a cogeneration plant capable of supplying 8,300 kWe of electrical power, replacing the existing plant.

Strengths

Replacement of existing system

Cefla has designed and installed a new cogeneration plant with an electrical power of 8,300 kWe to replace the existing one, improving the energy efficiency of the plant.

Energy and environmental savings

At full production capacity, the plant allows for annual savings of approximately 2,500 TOE (tonnes of oil equivalent), avoiding the emission of a significant amount of CO₂ into the atmosphere.

Key Numbers

8.300 kWe

Installed electrical power
about

2.500 TEP

Annual energy savings

7.400 h/years

Production hours

Background

Florim Ceramiche is a leading manufacturer of high-end ceramic surfaces. The Mordano plant needed a more efficient energy system to support production and reduce its environmental impact. Cefla responded to this need by designing and installing a new cogeneration plant.

The 56,000 m² expansion of the plant, designed according to the innovative principles of ‘Industry 4.0’, has enabled the installation of new lines for the production of large slabs and has doubled the factory's production capacity.

Challenges

  • Energy efficiency
    Improve the energy efficiency of the plant by replacing the existing system with a more efficient one.
  • Reduced environmental impact 
    Reduction in CO₂ emissions and energy resource savings.

Project Tasks

Cefla designed and installed a high-efficiency cogeneration plant, optimised for Florim Ceramiche's production needs. The project included replacing the existing plant and integrating the new system into the factory's production process.
Florim Ceramiche entrusted this project to Cefla, choosing a turnkey solution that included the supply of all ancillary works, such as civil works, mechanical connections and related structures, low and medium voltage electrical connections and energy monitoring equipment. The Centrax CX 300 2S turbogas unit, installed for the first time in Italy, is based on the innovative ‘twin-shaft’ turbine Siemens SGT- 300-2S (electrical efficiency 34.0%), coupled with a 15 kV synchronous alternator, which allows direct connection to the plant's medium voltage grid without the need for a step-up transformer.


Implementation

The configuration of the cogeneration plant was defined following an in-depth feasibility study conducted jointly by Cefla and Florim, which allowed for a comparison of the most advanced and efficient gas turbines currently available on the market and the identification of the size and model best suited to current and future energy requirements. The solution identified also allows for future upgrading of the turbine's performance with an increase in electrical power by an additional 800 kWe. The new gas turbine is connected to two Sacmi production atomizers: an ATM 140, already in use, and a newly installed ATM 65. The machine is capable of delivering thermal power of 16,220 kWth and supplying the two dryers with a hot air flow rate of 516°C equal to 106,200 kg/h. The Centrax CX 300 2S gas turbine unit, installed for the first time in Italy, is based on the innovative “twin-shaft” turbine Siemens SGT- 300-2S (electrical efficiency 34.0%), coupled with a 15 kV synchronous alternator, which allows direct connection to the plant's medium-voltage grid without the need for a step-up transformer. The possibility of operating at a gas pressure of 18 bar has made it possible to avoid the installation of a compression unit, directly using the pressure supplied by the grid. Cefla completed the supply with an innovative plant automation and supervision system that allows real-time remote monitoring of plant efficiency and economic return in accordance with the latest operating standards. Work began at the end of 2016 and the cogeneration plant was commissioned as planned by the end of August 2017. Thanks to the preparatory work carried out during the December production break, it was possible to build the new plant in parallel with the existing one, minimising downtime and energy supply from the grid. At full production capacity, the cogeneration plant will save approximately 2,500 TOE of oil per year, avoiding the emission of 5,800 tonnes of CO2 into the atmosphere.

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