AB Casehistory Smec EN
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Transcript of AB Casehistory Smec EN
AB | Case History
AB FORSMEC
COGENERATION FOR THE EFFICIENCY OF A PUBLIC HEATING NETWORK TARGETING AROUND 9,000
USERS IN THE NORTH MILAN AREA
AB IS A PARTNER OF SMEC, TO WHICH IT SUPPLIES
ENGINEERING, PRODUCTION AND
MAINTENANCE OF TWO COGENERATION PLANTS
INSTALLED AT THE REMOTE-CONTROLLED
HEATING POWER PLANT.
AB FOR SMEC
AB IS A PARTNER OF SMEC, TO WHICH IT SUPPLIES
ENGINEERING, PRODUCTION AND
MAINTENANCE OF TWO COGENERATION PLANTS
INSTALLED AT THE REMOTE-CONTROLLED
HEATING POWER PLANT.
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DISTRICT HEATING
Centralised combustion that is strictly controlled both in terms of efficiency and emissions. Elimination of boilers from buildings, resulting in a reduction of all relevant maintenance
expenses. Greater safety thanks to the elimination of all the risks of poor functioning of the boiler, the
gas line and chimney flue.
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DISTRICT HEATING ADVANTAGES ALL-ROUND:
USERS, LOCAL ADMINISTRATION AND THE ENVIRONMENT.
District heating is one of the most valid responses
that combines energy saving and eco-sustainability,
particularly in densely-populated urban and
industrial areas that often suffer problems caused
by high polluting emissions into the atmosphere.
The possibility of eliminating thousands of individual
boilers and developing a single, high efficiency,
centralised system to circulate hot water continues
to prove to be one of the safest and most efficient
choices in terms of green economy. Environmental
protection goes hand-in-hand with concrete benefits
for the user and local community as a whole.
Infrastructures linked to traditional individual
internal heat production systems are no longer
necessary, and the costs for their maintenance are
therefore also eliminated. But the advantages for
the user do not stop at merely economic benefits:
the lack of fuels and naked flames, replaced by the
centralised supply of hot or heated water, make
district heating a particularly safe system.
District heating provides a valid contribution to
improving air quality, particularly in the most badly-
affected urban environments. The generators used
in the cogeneration plants are extremely efficient
and constantly monitored by specialised staff. This,
together with the inclusion of efficient waste fume
purifiers, makes for a significant environmental
benefit. Clearly, savings in this sector can play an
important role in achieving local and national energy
saving policy objectives.
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COGENERATION
THE IDEAL PROCESS TO INCREASE AND FULLY EXPLOIT THE ADVANTAGES OF REMOTE HEATING.
BELOW ARE THE SENSATIONAL FIGURES OF THE POWER PLANT IN CINISELLO BALSAMO (MILAN) ACHIEVED THANKS TO THE TOP-PERFORMANCE OF AB SYSTEMS:
-24%FUEL
-99%SULPHUR OXIDES
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COGENERATION
The experience of the SMEC district heating plant
in Cinisello Balsamo represents a particularly
important case history that allows us to understand
the opportunities and advantages offered by district
heating, particularly if, in terms of technology
adopted, we focus on the potential of cogeneration.
The collaboration between SMEC and AB provides
concrete proof of how district heating can be decisive,
without necessarily having to use a large-scale plant.
With regards to the Cinisello district heating network,
the data is all too clear: savings of approximately
24% on fuel have been calculated, along with a
reduction of 99% of sulphur oxides, 49% of dust,
28% of nitrogen oxide and a 27% reduction in carbon
dioxide. With regards to the possible outcome on the
emissions in the surrounding environment, both the
carbon oxide values (NOx) ad carbon monoxide (CO)
values, respectively estimated as 50 mg and 40 mg,
are well below the legal limits, which must be lower
than 100 mg for NOx and 200 mg for CO.
Also with regards the acoustic impact, 48 decibels
were estimated from cogeneration and 55 for the plant
in an industrial area where limits are established
as 70 decibels by day and 60 by night. In short, the
use of the cogeneration plant combined with district
heating has absolutely no negative impact on the
territory. In addition to the advantages described
above, we also enjoy a significant economic return
for the local administration, deriving from the fees
for the concession to use public subsoil.
-28%NITROGEN OXIDE
-27%CARBON DIOXIDE
-49%DUST
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THE PROJECT
From a technical-architectonic viewpoint too, the plant has been
developed in complete respect of the environment.
To this end, the project envisaged the burying of part of it in order
to limit the height of the constructions on the road side, in full
compliance with landscaping and environmental constraints.
Respect of limits to emissions released into the atmosphere, which
are well above legal parameters, is guaranteed by an elimination
device and continuous monitoring system.
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THE PROJECT SMEC DEVELOPED THE COMPLETE
PROJECT AND MANAGES THE PLANT IN CLOSE
COLLABORATION WITH THE CINISELLO LOCAL
COUNCIL.
The plant falls under a specific ‘Local Energy Plan’
drawn up by the Administration of Cinisello Balsamo
and destined to result in energy, and therefore
economic, savings for users, but above all to help
decrease atmospheric emissions produced by the
individual boilers. The local council of Cinisello
Balsamo has authorized the development of the
district heating network by signing an agreement
granting permission for the use of its subsoil, in
response to public interest in energy, economic
and environmental benefits. SMEC (Società
Multiservizi Energia Cinisello Balsamo) is a multi-
service company set up specifically to develop the
district heating network in Cinisello powered by a
cogeneration plant.
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The plant has been operative since October 2009,
standing on an area measuring approximately
2,700 square metres in the industrial estate to the
northwest of the city of Cinisello Balsamo, on the
border with Muggiò. It allows for the simultaneous
production of heat and electricity, saving on fuel as
it uses part of the heat deriving from the electricity
generation process to produce thermal energy.
The plant was designed in the complex by
professionals appointed by SMEC, whilst AB developed
all the engineering aspects of the cogeneration part,
consisting of two natural gas-fuelled engines, each
with an electrical power of 2,400 kW, allowing for the
thermal recovery of 2,600 kW, and four boilers, again
fuelled by natural gas, each able to supply 7,800 kW.
Both the cogeneration engines and the boilers are
connected to chimney flues measuring approximately
20 metres. The entire plant supplies energy to
approximately 9 thousand medium-sized apartments
and public buildings, such as the various schools of
the area.
The work was approved with the favourable opinion
of all applicable competent authorities: Arpa, the
Provincial Authorities of Milan, the Fire Brigade, Asl3
health authorities and the safety at work service.
More specifically, the plant is equipped with a
continuous emissions release monitoring and control
system. The supply network is entirely underground,
extending for 12 km. A collector runs parallel to the
network, in which all the subservices are located.
2NATURAL GAS
ENGINES, EACH WITH A POWER OF
2,400 kW
4NATURAL GAS
BOILERS, EACH ABLE TO SUPPLY 7,800 kW THERMAL ENERGY
12kM DISTRICT
HEATING NETWORk
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8MONTHS TO
DEVELOP THE PLANT
3YEARS TO
COMPLETE THE NETWORk
9.000THOUSAND
PRIVATE, PUBLIC AND COOPERATIVE HOUSING USERS
SERVED
The Cinisello Balsamo district heating network envisages three lots: complete installation will take three years, the first lot is currently operative (green line).By end 2010, the plant will connect 62 buildings for a total of 3,111 families.
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ECOMAx®
FOR THE DISTRICT HEATING PLANT OF CINISELLO BALSAMO, AB HAS SUPPLIED AND INSTALLED TWO ECOMAX® 24 NGS COGENERATION PLANTS.
The development of the district heating plant of
Cinisello Balsamo provides important evidence
of how AB works and just what it can offer a
customer with regards to this type of plant.
The case history shows, in fact, how AB is a
partner to the customer in all aspects of project
development: collaboration in defining the
feasibility plan and optimisation of the ‘plant
system’; proper technology engineering; plant
production at its Orzinuovi plants, installation
and start-up in accordance with timescales
agreed with the customer, which, in this case,
specified a fundamental date: the start of the
2009 thermal season to satisfy users who were
already connected.
All this in addition to the availability of assistance
and maintenance services provided directly by the
AB Service company.
PLANTS
2xEcomax® 24 NGS
Fuel consumption Nm3/h 583
Power input kW 5,534
Electrical power kW 2,433
Electrical efficency % 44.0
Hot water production return °C 65
Delivery °CkW
95 2,273
Thermal efficency % 41.0
Total performance % 85
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≤
ECOMAx®
PLANTS
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Alongside the supply of the cogeneration part
of the plant, consisting of two ECOMAX® 24, AB
also dealt with the many accessory works that
were fundamental to optimal plant efficiency
and reliability. More specifically, AB skills
managed all the technical aspects in relation to
plant systems, including the pump stations and
expansion systems. non-cogeneration boilers
were also installed with the relevant connection
systems to the district heating network.
The work carried out to eliminate fumes was also
important, with the development and installation
of special insulated chimneys.
Engineering and installation of the electrical
part of the entire plant, both in terms of the
command/control cabins and to develop an
integrated monitoring system of the release of
emissions into the atmosphere. Amongst the
other demands met, we should mention those in
relation to the emergency generators and safety
systems.
NOx: Nitrogen oxidesCO: Carbon monoxide
CO2: Carbon monoxideSO2: Sulphur oxides
Current scenarioFuture scenario
0,001,000,00
3,000,004,000,005,000,006,000,007,000,00
0,0020,000,000,0040,000,000,0060,000,000,0080,000,000,00
100,000,000,00120,000,000,00140,000,000,00160,000,000,00180,000,000,00200,000,000,00
0,00
5,000,00
10,000,00
15,000,00
20,000,00
25,000,00
0,0050,00
100,00150,00200,00250,00300,00350,00400,00450,00
0,00
5,000,000,00
10,000,000,00
15,000,000,00
20,000,000,00
25,000,000,00
0,002,000,004,000,006,000,008,000,00
10,000,0012,000,0014,000,00
NOx CO FUMES DUST CO2 SO2
2,000,00
EXPECTED BENEFITS
The pollutant emissions that have already been avoided are:SO2 3,000 kg/year Fine dust 53 kg/year NOx 1,500 kg/year CO2 400 kg/year CO2 1,400,000 kg/year Fumes 11,000,000 kg/year
NOx: Nitrogen oxidesCO: Carbon monoxide
CO2: Carbon monoxideSO2: Sulphur oxides
Current scenarioFuture scenario
0,001,000,00
3,000,004,000,005,000,006,000,007,000,00
0,0020,000,000,0040,000,000,0060,000,000,0080,000,000,00
100,000,000,00120,000,000,00140,000,000,00160,000,000,00180,000,000,00200,000,000,00
0,00
5,000,00
10,000,00
15,000,00
20,000,00
25,000,00
0,0050,00
100,00150,00200,00250,00300,00350,00400,00450,00
0,00
5,000,000,00
10,000,000,00
15,000,000,00
20,000,000,00
25,000,000,00
0,002,000,004,000,006,000,008,000,00
10,000,0012,000,0014,000,00
NOx CO FUMES DUST CO2 SO2
2,000,00
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METICULOUS COMPLIANCE WITH THE STRICT SUPPLY TIMETABLE AGREED WITH THE CUSTOMER.
WORKS SCHEDULE
6February March April May June July August September October Month
Week 7 8 9 10 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 46 47December50 51 52 53 1 248 494443 45 341 42
Year 2009 2010
Design Pre-manufacture in the workshopPower plant design Pre-manufacture in the workshop Assembly Start-up Continuous operation
4January
11November
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PLANT PERFORMANCE IN THE WORDS OF THOSE USING IT.
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What led you to choose cogeneration and the collaboration with AB?“The entrepreneurial and technical staff currently working in SMEC has matured significant experience in the design and development of district heating networks, and were able to assess the validity of choosing cogeneration as the best solution by which to optimise the plant’s thermal efficency. More specifically, cogeneration allowed us to obtain the constant basic thermal energy necessary to the network in optimal efficiency conditions. The thermal energy originating from the cogeneration plant forms the ‘hard core’ of the heat that always remains active and available. Cogeneration plants are, alone, sufficient to allow for the functioning of the district heating network for much of the year. At the coldest times, or where specific requirements exist, we use natural gas-powered boilers. With AB we developed a plant in Rho, in very similar conditions to those of Cinisello. At that time we were able to note with great satisfaction, the skill and willingness to collaborate towards achieving the very best results, starting from the specific logistical conditions and needs of the social context in which the plant was to be developed. With the staff of AB we were able to complete exactly the plant we were looking to obtain in Cinisello, in terms of characteristics and performance, within the scheduled timescale. We have found AB to be a multi-disciplinary system integrator able to offer a truly turnkey solution that goes well beyond the simple supply of a cogeneration plant. We have found a problem-solving reality that was able to intervene competently in the many technical specificities existing during the fitting-out of a plant such as this one”.
Now that the plant is fully functioning, are you happy with the results achieved?“We are very happy indeed with the work completed and how the results are showing that this was the right choice, demonstrating the validity of a project that we strived tenaciously to attain. The plant has proved itself to be of great value to the entire community of Cinisello. Right from the very first thermal season, the benefits were clear, both in terms of service commodity and with regards to optimising energy costs that, we should not forget, also means less need for maintenance of individual boilers. We should also then remember that the plant allows for a significant elimination of polluting substances due to the many boilers, often using obsolete technology or maintained poorly”.
To what extent can the district heating plant be considered a ‘pilot project’?“It is a pilot project from every point of view: technology, dimensions, performance and scale economy. The SMEC network and plant thereby shows just what can be done in critical areas from a town planning and co-environmental viewpoint. Up until a short while ago, it was thought that district heating was only suitable for large communities and cities: today, the benefits of focussed action on a local level are clear to all. The first to realise it are the local administrations, who at the same time can note with great satisfaction just how useful it can be to begin public-private collaborations on the matter”.
Eng. Silvio Vezza (Operative Manager SMEC)
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AB
HO
LDIN
G S
PA
AB Ambiente Srl
AB SETS THE
COGENERATION STANDARDS
GLOBALLYAB INDUSTRIAL GROUP HAS
BEEN OPERATING FOR OVER
30 YEARS IN THE SECTOR
OF COGENERATION AND
PROMOTION OF ENERGY
FROM RENEWABLE
SOURCES.
AB Energy SpAITA LYSALES
AB Plants Srl AB Power SrlPRODUCTION
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KWE Technika Energetyczna Sp. z.o.o.
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Green House Power Netherlands BV
EPS AB Energy Canada Ltd.
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FOREIGNBRANCHES
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AB is currently made up of 24 companies and over 500 employees and is a single entity able to manage the entire manufacturing cycle of a cogeneration plant: consultancy, design, production, installation and start-up with a comprehensive service. This has enabled AB to acquire unparalleled know-how, to become acquainted with every product detail and to provide a top-quality and highly-effective after-sales service. The success of AB - which has already designed and built more than 900 plants - stems from ongoing investments in cutting-edge technologies, from the constant training and professional specialisation of all operators and from the development of an absolutely unique engineering
department: a team of over 110 engineers engaged in developing the industry towards the production of increasingly more reliable and higher performance plants. AB cogeneration plants are distinguished by modularity, compactness and ease of transport and cater to the energy requirements of a number of different companies. Outright leader in Italy, AB is also expanding globally: in Spain (2007), in Romania (2009), in Poland (2010), and again with the opening of subsidiaries in Croatia and Serbia (2011). From 2012 AB is in Czech Republic, from 2013 also in the Netherlands, Austria, Brazil, Francia and Canada. From 2014 AB in Uk, Germany, USA and Israel and from 2015 in Russia and Turkey too.
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Cogeneration has proven to be a winning choice, also in other industrial and non-industrial fields, such as food chemical, pharmaceutical, textile, plastic, paper, brick, etc.
700 customers, some of them are:Amadori, Benetton, BNL, Buitoni, Cartiere Saci, Coca - Cola, Cotonificio Albini, Eridania, Esselunga, Fatro, Ferrero, Felli Color, Galbani, Garda Plast, Granarolo, Gruppo Cremonini, Gruppo Mapei, kraft, Lafarge, Lilly, Martini & Rossi, Nestlè, Orogel, Pastificio Garofalo, Pastificio Rummo, Peroni, Pfizer, Polynt, Spumador, Wienerberger, etc.
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AB Energy SpAVia Caduti del Lavoro, 13 25034 Orzinuovi BS - ItalyT. +39 030 94 00 100www.gruppoab.com