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Nuova Riwal Ceramiche

Power Generation for Nuova Riwal Ceramiche
Power Generation
Customer Nuova Riwal Ceramiche
Where Maranello (MO)
Solution Power generation
Sector Industrial

Nuova Riwal Ceramiche has equipped its SAIME plant in Maranello with a high energy efficiency cogeneration system.

Strengths

Turnkey solution

Cefla designed, built and installed a complete cogeneration plant, replacing the previous system dating back to 1992.

Energy efficiency greater than 95%

The plant has obtained CAR (High Efficiency Cogeneration) classification, maximising the use of primary energy and allowing access to energy efficiency certificates and tax relief provided for SEU systems.

Integration with production process

The recovered thermal energy directly powers the atomizers in the body preparation department, optimising the production cycle.

Advanced control and supervision system

It allows cogeneration to be used to achieve maximum efficiency, adapting to variations in electrical loads and ensuring maximum heat recovery.

Key Numbers

4,4 MWe

Installed electrical power

>95%

Overall efficiency

9.500 kW

Heat output from flue gases

Background

Nuova Riwal Ceramiche, part of the Casalgrande Padana group, is an Italian manufacturer of porcelain stoneware tiles. The Saime plant in Maranello needed an energy upgrade to meet growing energy demands and improve the sustainability of its production processes.

The electricity produced independently by this new power plant will be used to power the renovated production facilities, while the thermal energy is completely recovered by the atomizers in the body preparation department.

Challenges

  • Meeting growing energy needs
    With the expansion of the plant, it was necessary to ensure an adequate and sustainable energy supply.
  • Optimising efficiency
    Integrating the cogeneration plant with the new production lines to maximise energy efficiency.

Project Tasks

Cefla Engineering supplied a cogeneration plant based on a 4.4 MWe gas turbine, with heat recovery exceeding 95%. The thermal energy is used to power the atomizers in the body preparation department, improving the efficiency of the production process.

Implementation

The electricity, produced independently thanks to this new 4.4 MWe power plant, is used to power the renovated production plants, while the thermal energy is completely recovered from the atomizers in the body preparation department.
The supply is completed by the gas compression system required for the turbine to operate correctly. The entire system is designed for extremely high energy efficiency: up to over 95% compared to the energy introduced as natural gas, allowing it to be classified as ‘High Efficiency Cogeneration’.
The new plant was completed with a supervision system developed by Cefla with automated control logic, which is useful for managing the machine according to various process conditions. The two most interesting modes are electrical tracking, which minimises energy transfer to the grid, and thermal tracking, which allows for complete heat recovery from the fumes. This second mode allows for very precise management of energy indices on an annual basis and, given the current economic conditions of the energy market, also allows for economic gains through the sale of energy to the grid. The CAR (high-efficiency cogeneration) certification has allowed access to Type II-CAR energy efficiency certificates, as well as the benefits provided for SEU (Efficient User Systems) systems.
Working with Cefla's engineers, we were able to customise the supervision system to meet our specific needs (energy index management, reporting, cosfi control, etc.).
The plant was completed and successfully commissioned in 2016, contributing significantly to reducing the factory's energy costs and CO₂ emissions. The solution has enabled Nuova Riwal Ceramiche to improve the sustainability and competitiveness of its production process.

Gallery

Nuova Riwal Ceramiche
Nuova Riwal Ceramiche
Nuova Riwal Ceramiche
Nuova Riwal Ceramiche
Nuova Riwal Ceramiche
Nuova Riwal Ceramiche
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