Tecnoparco Valbasento

Power Generation per Cefla
Power Generation
Customer Tecnoparco Valbasento
Where Pisticci Scalo (MT)
Solution Power Generation
Sector Servizi ambientali

Cutting-edge technology, energy efficiency, and a low environmental impact are the hallmarks of the revamping of the Tecnoparco Valbasento cogeneration plant. This project is an integral part of the advanced routine and extraordinary maintenance service that Cefla has been providing continuously since 2008.

Strengths

New motor generators

Replacement of the 4 existing cogenerators with 3 new high-efficiency motor generators.

Thermal recovery

Thermal recovery of heat from the exhaust fumes of the motor generators, via 3 superheated steam boilers.

Riduzione delle emissioni inquinanti

Installation of the SCR system to reduce polluting emissions into the atmosphere.

Key Numbers

23,4 MW

Total electrical power

2.150 kW

Recovery boiler power

18 MWt

Maximum heat capacity that can be dissipated by the evaporation tower

Background

Tecnoparco Valbasento provides energy and environmental services to manufacturing and service industries located in the Pisticci industrial park (Matera).

Since 1990, the company has been providing infrastructure for the production and distribution of electricity and heat, technical gases (compressed air, nitrogen), and water for industrial uses, as well as the treatment of wastewater and liquid waste. Infrastructure and services (engineering, analysis laboratories, transportation, security, maintenance, etc.) are characterized by rigorous quality, energy, and environmental standards, creating a favorable environment for the development of industrial activities.

As part of the capacity market development tenders, Tecnoparco Valbasento won the tender for the supply of 20 MW of electrical power. Cefla oversaw the subsequent revamping of the CHP (combined heat and power) plant, significantly improving the efficiency and sustainability of the industrial complex.

Challenges

  • Completely dismantle and replace the existing power plant, integrating some pre-existing structures into the new configuration.
  • Increase available power and improve the plant's energy efficiency, avoiding further land consumption.
  • Ensure full compliance with current regulations regarding emissions control and reduction from new electric and thermal generators.

Project Tasks

Since 2008, Cefla has been responsible for the ordinary and extraordinary maintenance of both the cogeneration plant and the biofuel-fired power plant, both located within the technology hub.

The project involved replacing the four existing engines (each 5 MW) with three new high-efficiency motor-generator units (each 7.8 MW), powered by natural gas (electrical efficiency 48.9%). The renovated plant now has a total electrical output of 23.4 MW. The units are equipped with an advanced heat recovery system that, through the existing collector, feeds three new boilers (each 2,479 kWt) for the production of superheated steam at 271°C (9 t/h total), which is also used in production activities. The new generators are cooled by a modular evaporation tower with eight modules (each 2,335 kW), while atmospheric emissions are minimized by the SCR (Selective Catalytic Reduction) system.

Assuming the current CHP plant operates for 8,000 hours per year, the reduction in greenhouse gas emissions is estimated at 14,400 tCO2 per year.

Implementation

The revamping project was designed and implemented by Cefla in close collaboration with Tecnopolo Valbasento, using technologically advanced solutions geared towards energy efficiency. During the dismantling of the existing plant, the thermal collector was recovered and modified to adapt to new requirements. The main installation activities involved:

  • motor-generator units (Wartsila mod. 16V34 SG)

     

  • superheated steam generators (Tecnoterm mod. RE-VAP)

     

  • evaporative cooling towers (Baltimore, 180 m3/h flow rate)

     

  • SCR system for emission reduction


    The revamping project consolidated the energy efficiency and sustainability of Tecnoparco Valbasento, ensuring electricity and steam supply to numerous companies in the district. The power, flexibility of use, and technological features of the new CHP plant allow for optimized management of energy resources, fully complying with environmental objectives.

    The project was completed at the end of 2023, with full operation expected in June 2024. CEFLA continues its routine maintenance activities for CHP and biofuel-fired power plants, relying on advanced preventive, corrective, and predictive maintenance systems such as CMMS.

     

Gallery

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