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Kaleseramic

Cogeneration plant for two factories
Power Generation
Customer Kaleseramic
Where Çanakkale and Kalebodur, Turkey
Solution Power Generation
Sector Industrial, district heating

Kaleseramik has entrusted Cefla Impianti with upgrading the control and supervision system for the entire cogeneration plant at its two factories in Cannakale and Kalebodur, which make up the Can plant, as well as engineering for the installation of a new atomiser.

Strengths

Advanced digitisation

Cefla has implemented a state-of-the-art control and supervision system for the entire cogeneration plant, improving operational efficiency and energy management.

Multi-site integration

The new system enables centralised management of Kaleseramik's two factories, located in Çanakkale and Kalebodur, optimising operations and maintenance.

Reliability and safety

The upgrade has improved the operational safety and resilience of the plant, ensuring continuous and reliable energy production.

Key Numbers

2

Plants involved

22.500 kWe

Electrical power

Background

Kaleseramik is one of Turkey's leading ceramic manufacturers, with a significant market presence internationally. The company operates two major plants in Çanakkale and Kalebodur, where efficient and sustainable production is key to maintaining competitiveness.

The partnership between Cefla and Kaleseramik began over 20 years ago with the construction of a cogeneration plant that enabled the company to significantly reduce its emissions and energy costs.

Challenges

  • Technological modernisation
    Upgrade of an existing control system to meet current efficiency and sustainability requirements.
  • Business continuity
    Implementing the upgrade without disrupting daily production operations.
  • Staff training
    Ensuring that the internal team is adequately trained to use the new system effectively.

Project Tasks

Cefla designed and implemented a customised control and supervision system for Kaleseramik's cogeneration plant. The project included the installation of advanced hardware and software, integration with existing systems and staff training to ensure a smooth and efficient transition.

Implementation

The project was successfully completed, with an immediate positive impact on energy efficiency and operational management at Kaleseramik's plants. The upgrade has helped strengthen the company's position as a leader in the ceramics industry, highlighting the importance of technological innovation in industrial production.

The project involved the installation of a new atomiser with a water evaporation capacity of 25,000 litres per hour, connected to the existing cogeneration system and an additional system to recover heat from the kilns in order to maximise the use of existing thermal energy.

Cefla was responsible for the design and manufacture of the main mechanical components, instrumentation and components for the heat recovery system, as well as the supply of automation and supervision control devices (software and hardware). The advanced automation system allows one or more turbines to be used depending on the electrical energy required by the plants. Three Siemens gas turbines, with a total power of 21 MW, feed nine atomizers through their exhausts and supply electricity to all the plants. A fibre optic network transfers the control signal for all units at high speed, while the new software ensures monitoring of the entire system through an intuitive user interface, constant recording and reporting of functional data.

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