AB FORVINAVIL

(Mapei Group)

CoGeNeraTioN For THe eNerGY eFFiCieNCY oF THe aDHeSiVeS

CHeMiCaL iNDuSTrY

AB | Case History

AB for VINAVIL (MAPEI grouP)

LOW COSTS AVAILABILITY OF

ELECTRICITY AND THERMAL ENERGY,

BoTH AS STEAM AND HoT WATEr, IS A

CorPorATE MuST.

the COGeNeRAtION in the ADheSIVeS CheMICALPRODUCtION CYCLe.

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ELECTRICITY, STEAM AND HOT WATER FOR A PRODUCTION PROCESS THAT CONSTANTLY REQUIRES LOTS OF POWER IN ECO-SUSTAINABLE FORM.

the COGeNeRAtION in the ADheSIVeS CheMICALPRODUCtION CYCLe.

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Vinavil SpA is in the front line when it comes to commitment towards an environment-friendly “ecological chemical industry”. Energy efficiency is in fact considered an integral part of an eco-sustainable path leading to the optimisation of the production processes and the safeguarding of the environment. The low-cost availability of electricity and thermal energy, both in the form of steam and hot water, represents a corporate must. The adhesive production cycle does in fact use up large quantities of energy and represents a strategic economic factor. What the company needs therefore is to develop energy efficiency and obtain energy at low cost to achieve competitiveness on an increasingly more aggressive globalised market. The solution for the Villadossola (Verbania) facility was found in the AB ECOMAX® 14 NGS cogeneration plant. The AB plant, thanks to its better energy output, has made it possible to achieve excellent results in this direction, while at the same time cutting the yearly emissions of CO2 into the atmosphere by around 803 tonnes, thus confirming Vinavil’s close attention for the environment. A concrete and far-reaching decision to continue to enhance its technological heritage by combining competitiveness and ecosustainability.

Vinavil S.p.A. was established in 1994 following the

acquisition by the Mapei Group of the acetal-vinyl

polymer production business which formerly belonged to

EniChem Synthesis. Italian traditions thus continue in the

fine and secondary chemical industry, and the company

is quite rightly up among the European leaders in this

sector. Today it leads the field in Italy in the production

of dispersion polymers, with special reference to the

adhesives used in numerous application sectors, from

textiles to building and chemical processing. It has two

production facilities in Italy - at Villadossola (Verbania)

and at Ravenna. Vinavil also has production facilities at

Suez (EG) and, as part of the Mapei Group, in Chicago

(USA) and Montreal (CAN). The Vinavil brand, besides

within industry, has also been well known for decades

in homes and schools, thanks to the Vinavil universal

adhesive, the first and most famous glue for a variety

of home uses and which is used by students of all ages.

Through an extensive sales network and an effective

after-sales service, the company is able to cater to the

needs of its customer worldwide: 50% of its production is

in fact exported to over 40 different countries.

THe ViNaViLProDuCTIoN fACILITY

ofVILLADoSSoLA (VERBANIA).

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A COMPANY AT THE SERVICE OF INDUSTRY AND WELL-KNOWN TO THE GENERAL PUBLIC - IN SCHOOLS AND IN HOMES.

Vinavil is an Italian chemical industrial concern closely

focused on research and which bases its growth on

innovation and care for the environment, both by

upgrading existing products and regularly presenting

new alternatives. In 1995, Vinavil obtained UNI EN

ISO 9001 certification by joining the international

environment protection program “Responsible Care”.

What is more, in 2004 the Ravenna Facility obtained

ISO 14001 environment certification, also awarded to

the Villadossola facility in December 2007. In this very

production plant, major investments have been made

to protect the environment, including the installation of

a biological treatment unit and a vent gas combustion

unit. The Villadossola plant is involved above all in

the production of acetal-vinyl-based emulsions and

powders; it has a potential production output of around

150,000 t/year of glues. The finished products appear

like aqueous emulsions (the famous “white glue“) used

as adhesives in many different fields (manufacture of

paper, non-woven fabric, packaging, adhesives for wood

and plastic laminates, wall paintings, textile prints,

hobbies, etc.). For some years as well, the factory has

been processing liquid emulsions, by drying, to produce

adhesive powders, mainly used in the building trade

(adhesives for tiles, modified cements, etc.).

THe ViNaViLProDuCTIoN fACILITY

ofVILLADoSSoLA (VERBANIA).

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ecomax® 14 NGS

PCI natural gas kWh/Nmc 9.5

Natural-gas consumption Nmc/h 363

Introduced power kWt 3,446

Dispensed mechanical power kWe 1,451

Dispensed electric power kWe 1,416

Electric power kWe 1,363

Thermal power recovery kWt 1,495

Electrical output % 41.0

Thermal output % 40.0

Total output % 81.0

With the involvement of the AB engineers, a detailed analysis was performed of the

energy requirements of the Vinavil facility of Villadossola and of its already-existing

characteristics. This study showed the opportunities and benefits provided by an

ECOMAX® 14 NGS container cogeneration plant. The modular solution features

a natural-gas fuelled GE Jenbacher JGS 420 GS NL motor, with heat recycling

from the motor block (lubricant oil, intercooler, motor liners) by means of plate

exchanger for the production of hot water, including a fume recycling boiler for

the production of steam. The produced electricity is fully used within the company

production facility; any rare surpluses are yielded to the grid. The thermal energy

recycled from the motor cooling system and fume recycling boiler is used in the

facility for technological purposes in the form of hot water at 80°C and steam at

5 bar. The total thermal energy available for recycling, net of heat losses due to

dissipation and to the release of exhaust gases into the atmosphere, amounts

to 1,495 kWt, 652 kWt of which at high temperature (steam) and 843 kWt at low

temperature (hot water). Expected plant use is around 8000 hours/year. The

production and infrastructural activities of the facility are in fact continuous cycle

over 24 hours, seven days a week during the course of the entire year, except for

two stops made for summer and winter servicing (15 + 15 days).

THE CHoICE of CogENErATIoN AS BEST forM of EffICIENCY: THE ECOMAX® 14 NGS CONTAINER MODULE PLANT.

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The cogeneration plant for the Vinavil facility of Villadossola is located inside an industrial complex which, in terms of date of establishment and structural characteristics, required a specific feasibility study, with the harmonious development of modern technology and restrictions/restraints imposed by the conformation of the facility itself, which dates back to the 1930s. Further care had to be dedicated to the connection to the power mains, conditioned by infrastructures with numerous years of operation behind them, located on the border between Switzerland and Italy and which called for an updating project conducted jointly by the AB engineers and Vinavil. The already-existing plant-engineering situation in the facility also had to be taken into consideration. For the first time, this was to be integrated with cogeneration technology. Finally, a series of technical details and personalising features were needed, including a dual hot-water recycling system: demineralised water for supplying the boiler and industrial

803 tonnes of Co2 not emitted into the atmosphere every year

346 tonnes of fuel oil avoided every year

ViNaViL,PLANT CHARACTERISTICS.SPEAKING THE SAME LANGUAGE AS THOSE WITH AN ENGINEERING CULTURE.

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ViNaViL,PLANT CHARACTERISTICS.

water for various facility uses. All this resulted in the setting up of a dialogue between the AB technical staff and the Vinavil engineers, professionals with extensive experience acquired in Montedison and therefore used to managing an order of this type with authority and particular care. A positive and collaborative relationship was immediately built up, based on mutual consideration and on the exchange of experiences between operators which led to the devising of plant engineering solutions perfectly able to meet expectations. A result underscored by the reliability and efficiency of the plant on the 2010 test bench – the first complete year of operation during which the ECOMAX® 14 NGS produced electricity and thermal energy for 8,332 hours. It must also be calculated that in 2010, the Vinavil facility of Viladossola was closed for summer holidays for a total of 232 hours. The plant was therefore only shut down for the time strictly necessary to perform routine maintenance (oil change) and carry out a number of quick jobs on technical parts.

WORKS TIME SCHEDULE

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DesignWorkshop prefabrication Completion of building works AssembliesMaking connections Start-upsContinuative running

May June July August September October November DecemberWeekMonth

19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52

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pLaNT ouTpuT aCCorDiNG ToTHOSE WHO USE IT.

Interview with Ing. Patrizio Stecconi (Technical Manager of Vinavil SpA)

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Why did you choose cogeneration? what is the real benefit of a cogeneration plant in the chemical industry? “Our requirements involved combining a concrete ecosustainability action, something we have been committed to for years in order to cut CO2 emissions, with the optimisation of energy efficiency in our production facilities. In the chemical industry, cogeneration has shown itself to be ideal because both electricity and thermal energy can be obtained from the same plant, with the simultaneous production of hot water and steam. The latter, in particular, is essential in many production cycle stages and procedures”.

Why did you decide to have aB build the plant? “We conducted a widespread survey to identify the solution best suited to our needs and find a technological partner able to meet our expectations. AB, thanks to its experience and its ability to tackle the order with close focus on demands and on the real needs of the customer, seemed to us to be the ideal partner”.

How has the cogeneration plant built by aB integrated with your plant engineering situation and existing energy dynamics? A turbine-plant solution, considering that future growth prospects contemplated the need for large quantities of steam. Then this scenario began to change and, after analysing the various application perspectives with the AB engineers, we decided to opt for the ECOMAX® 14 NGS modular solution. At first, we were somewhat dubious about the fact that a 1495 kWt installation could best satisfy our thermal energy requirements. We believed it would be best to opt for cogeneration technologies with higher performances so as to integrate them with the already-existing setup. But we went on to entrust ourselves to the AB engineers and results have been absolutely excellent. It should be recalled that the current thermal energy demand of our Villadossola facility is around 3

tonnes of steam and 14 tonnes of hot water an hour, obtained using traditional natural-gas boilers”.

Have you already been able to determine its efficiency with respect to the expected benefit? “Yes, today we can answer that question in the affirmative. With the ECOMAX® 14 NGS, which has been operating for over a year now at 100% of its potential and without ever giving any problems, we have at disposal around one tonne of steam every hour and, at the same time, are able to heat up about 3 tonnes of water from 10 to 80°C. The steam is used in the production process, while the hot water is used for both the production lines and to heat the work environments. The electricity is nearly all used for the requirements of our facilities. Shortly, the scheduled use of hot water for non-continuative purposes will be put into place. This will enable us to completely recycle the so-called “low-quality heat” produced by the endothermic motor, thus further increasing the level of energy-efficiency of our production processes”.

What are expectations as regards the servicing of such a complex plant? “Dialogue with AB also includes assistance and maintenance requests, catered to by means of a dedicated round-the-clock service available every day of the year. This positively swayed the final decision to place the order with the Orzinuovi Group – the reliability of an after-sales service which is not only prompt but also performed by those who designed and built the plant gives us a certain peace of mind and the certainty of continuing energy supplies for our production processes.”

pLaNT ouTpuT aCCorDiNG ToTHOSE WHO USE IT.

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green House Power Netherlands BV

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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.

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