Sacmi

Power Generation for SACMI
Power Generation
Customer SACMI
Where Imola (BO)
Solution Power generation
Sector Executive

Cefla designed, supplied and installed an Easypower_G1200 trigeneration plant running on natural gas, with heat recovery from the engine cooling circuit and combustion fumes.

Strengths

Customised solution

Cefla has designed and built a methane-powered trigeneration plant integrated with SACMI's ceramic production process.

Energy efficiency

The plant enables the combined production of electricity, heat and cooling, optimising energy consumption and reducing emissions.

Integration with the production process

The system has been designed to directly power the plant's heating and cooling systems, improving overall efficiency.

Key Numbers

2.771 kW

Power introduced with fuel

1.203 kWe

Electricity output at generator terminals

2.771 kW

Power introduced with fuel

1.237 kWt

Recoverable heat output

Background

SACMI is an international group based in Imola, a leading supplier of plants and machinery for the ceramic industry and other sectors. The company is committed to sustainability and technological innovation, and the implementation of the trigeneration plant is part of this strategy to improve energy efficiency and reduce the environmental impact of its activities.

The plant is designed to be highly efficient, up to over 85% compared to natural gas, thanks to the electrical efficiency of the engine and the complete recovery of cogenerated thermal energy, which allows it to be classified as High Efficiency Cogeneration.

Challenges

  • Integration with existing processes
    Adapting the trigeneration plant to SACMI's specific production requirements, ensuring operational continuity.
  • Energy optimisation
    Maximising plant efficiency to achieve the best results in terms of energy savings and emissions reduction.
  • Turnkey supply
    The supply also includes connections to the thermal utilities identified together with the customer, in particular three thermal power plants and a refrigeration plant, designed for air conditioning of the production rooms and precision machining rooms under controlled atmosphere conditions.

Project Tasks

Cefla oversaw the design, supply and installation of the trigeneration plant, ensuring full integration with SACMI's existing infrastructure. The project included the implementation of advanced control systems to monitor and optimise plant performance.
The plant consists of a GE Jenbacher JMS 416 cogeneration unit, comprising a reciprocating engine (Otto cycle) fuelled by natural gas and directly coupled to a three-phase synchronous electric generator.
The unit, complete with all auxiliary devices necessary for operation and a containment package, is designed to dissipate the engine's radiant energy and reduce noise to 55 dB at 10 m.
In addition to the cogeneration package, the system is configured to recover the thermal energy present in the internal circuits of the engine (first stage of the intercooler, lubricating oil, liners) and that contained in the exhaust gases in the form of:
Hot water at 95°C for use in the heating and air conditioning system;
Chilled water at 7°C for the air conditioning system, produced by installing an absorption refrigeration unit powered by the same 95°C water from heat recovery.
The low-temperature energy (approx. 40°C) from the intercooler circuit is dissipated into the atmosphere.

Implementation

The project was completed in 2018, on schedule and within budget. The plant has enabled Nupi Industrie Italiane to improve the energy efficiency of its factory, reduce CO₂ emissions and optimise production processes thanks to a flexible and reliable energy supply.
Technopolymers and plant engineering challenges in the era of energy optimisation
The plant is powered by natural gas and electricity is produced by an internal combustion engine connected to an alternator. Through a lithium bromide absorber, the thermal energy produced by the system is in turn transformed into cooling energy, which is used to cool the extrusion plants used in the factory. What makes this plant the first of its kind is that pre-insulated NIRON technopolymer pipes have been used instead of traditional steel pipes.
Cefla's pre-insulated pipes were used to transport the heat transfer fluid to the users, creating a heating network that allows the necessary calories to be transported to the company's heating plant, and a cooling network for transporting refrigeration to the users: refrigerators and injection moulding machines used to mould our products. The system allows the water to reach the systems at almost the same temperature as when it leaves the heating and cooling plant.
This innovative system of pre-insulated pipes and fittings is ideal for applications where reducing heat loss is of paramount importance.
In addition to their excellent technical performance, NIRON pipes are lighter than steel pipes and require easier processes for fixing joints. This has greatly simplified handling and installation, with significant savings in construction time. The plant, which came into operation nine months after obtaining the necessary authorisations, has become a case study for its efficiency.

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