AB | Case History

AB FOR AMADORI

Cogeneration in an integrated energyeffiCienCy plan for the food seCtor

AB FOR AMADORI

AB Is AMADORI’s pARtneR BOtH

FOR tHe plAnts In pOweR stAtIOns powered with

natural gasAnD FOR

the modular biogas plants.

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cogeneration

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Considering the particular energy

intensive nature of the sector,

cogeneration is the ideal solution

for the food industry also because

it allows the supply chain waste

to be used to produce biogas. the

decisions made by the Amadori in

the field of energy efficiency highlight

the advantages that cogeneration can

offer very well, adding an element that

makes the case history even more

significant: the integration of plants

powered with natural gas and biogas.

the choice of cogeneration therefore

corresponds to an entrepreneurial

philosophy that greatly focuses at

the optimization of consumption,

the operability of the supply chain

and at eco-sustainability. A further

testimony to how the most dynamic

companies of the sector are looking

for solid solutions properly tested

and immediately feasible to lower

their costs and improve their energy

efficiency.

Is stRAteGIC FOR tHe FOOD seCtOR

tHe supply CHAIns OF tHe FOOD InDustRy ARe HIGHly eneRGy IntensIve AnD use lARGe quAntItIes OF steAM, HOt wAteR AnD COlD wAteR.

ration

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pAssIOn, ORGAnIzAtIOn AnD teCHnOlOGy.amadori.

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amadori.

with six sites fitted with state-of-

the-art technology, the Amadori

is one of the main industrial

companies in the poultry sector:

it combines a focus on Made in

Italy quality with an organizational

vision of european scale. Amadori

employs more than 7000 people of

80 different nationalities. It proposes

around 1700 references and over

500 products. the company directly

manages the entire integrated

supply chain: in this way it can

guarantee the origin of all the raw

material and control on each stage

of the production cycle, also thanks

to an internal traceability system.

Involved in every stage from animal

feed production to rearing, from

incubators to food processing sites

and distribution, Amadori certifies

the quality of processes and products

to offer quality, safety and taste on

the market. In particular, the food

processing sites, all recognized

by the public authorities in charge

and certified IsO 9001, host various

types of production lines of both

traditional and innovative products.

the basic ingredients of each

process are the passion for Italian

food tradition and the awareness of

modern food demand which allow

specialities to be created able to

satisfy the requirements of even the

most demanding consumers.

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A stROnG COMMItMent tO

eCo-sustainability.At the Amadori’s six Italian sites there is a large

emphasis on energy efficiency and the protection of

the environment.

In fact the Company has always been committed to

developing in harmony with the area where its sites

are located, aiming at finding a balance between

reduction of the consumption and the increase of

energy efficiency.

In fact over 50% of the electrical energy that Amadori

uses comes from renewable sources, according to

a green economy philosophy that also includes the

development of an energy efficiency plan which has

cogeneration as its main applied technology. the fact

that the Amadori has chosen to aim at cogeneration

with AB is a further testimony of the large focus

reserved for this technology, which is integrated with

a general innovation plan dedicated to energy and

eco-sustainability.

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eCo-sustainability.

Campese Amadori: range chicken.

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mosCianosant’angelo

tHe eneRGy eFFICIenCy neeDs OF tHe

sIte

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mosCianosant’angelo

sIte

A first important intervention of structural innovation

carried out by the Amadori in the field of energy

efficiency was directed at the factory located in

Mosciano sant’Angelo, in the province of teramo.

Here a cogeneration ecomax®bio plant designed

and produced by AB has been installed with the

aim to enhance the biomass originating from the

supply chain waste. the plant is in fact fuelled with

the biogas obtained by anaerobic digestion of fats

and proteins as well as breadcrumbs waste, which

contains oil and bread left over from the deep fryer.

Around 16,000 kilograms of organic load feed the

digester each day. via the ecomax®bio plant thermal

energy is obtained and fully used inside the site along

with electrical energy, which is entirely injected into

the grid.

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ecomax® bio is the plant design solution that applies the

distinguishing features of this exclusive AB technology to

the biogas power field. to meet the demands of Amadori’s

Mosciano sant’Angelo site, the AB specialists advised

the installation of ecomax® 6 bio in a configuration

fine-tuned to the specific needs of the site so that they

integrate perfectly with the already existing systems, in

particular as regards the use flows of thermal energy.

the system produces 14,800 kwh of electrical energy

which completely injected into the grid and 16,000 kwh of

thermal energy both from the recovery of the combustion

fumes (10 bar steam) that all sent inside the site, and

from the hot water of the engine, 50% of which is used for

the needs of the production site and 50% for reheating the

digesters.

the modular cogeneration package plant ecomax®

stands out as one of a kind thank to its design and

production models and processes, which are the result

of applied research and thirty years’ experience of AB.

ecomax® is an industrial product based on principles of

versatility, modularity, and compactness, and capable

of combining these distinctive characteristics with high

energy performance. An idea thought up and developed

entirely at AB, which is the main technological and market

reference point of modern cogeneration both in terms of

product range and possibilities of application.

layout ecomax® 6 BIO

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ecomax® 6 bio

THE Ecomax®

PLANT

Power biogas

Biogas flow rate Nm3/h 313

Electric power produced kWe 625

Total electrical efficiency % 40

Thermal power produced:

from engine cooling water kW 381

from exhaust gas fumes kW 381

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Cesenathe energy hub

At AMADORI’s

sIte

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The Technological sysTem includes a Thermal power sTaTion inTegraTed wiTh Two cogeneraTion planTs powered wiTh naTural gas.This is combined wiTh an anaerobic digesTer for exploiTaTion of wasTe (biogas) deriving from The slaughTering process.

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At Amadori’s Cesena site a real “energy hub” has been realized which

includes a thermal power station integrated with two cogeneration plants

powered with natural gas, respectively of 3 and 4 mwe. the integration

between the thermal power station and two cogenerators insures a very

high performance and a better distribution of the heat vector.

the three steam generators (boilers) in fact have a yield of 95% (usually

yield does not exceed 92%); moreover the system uses a distribution

method of the heat vector (hot water and steam) which was designed to use

heat waste from the cogenerate as effectively as possible and limit energy

waste. the high efficiency of the new hub allows a saving of around 3,600

toe (tonnes of Oil equivalent) corresponding to around 10,000 tonnes/year

of Co2 not emitted into the atmosphere, which is equal to a pes (primary

energy saving) above 20%.

ab teChnologies powered with

natural gas

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ab teChnologies powered with

natural gas At tHe CesenA

eneRGy HuB

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bioCogenerationIn tHe CesenA eneRGy HuB

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ecomax® 11 bio

layout ecomax® 11 BIO

At the Amadori’s Cesena site an anaerobic

digester has also been installed for processing

the waste from the slaughtering process and

allow to recover biogas from the cleaning

cycle. the biodigestion system in fact treats

the waste from the slaughtering process and

thus obtain an amount of biogas sufficient to

power a 1 mwe cogeneration plant, with the

complete use of heat waste. In this way around

1500 toe (tonnes of Oil equivalent) are saved

corresponding to around 4000 tonnes/year of

Co2 not emitted into the atmosphere.

Power biogas

Biogas flow rate Nm3/h 540

Electric power produced kWe 999

Thermal power produced:

from engine cooling water kW 578

from exhaust gas fumes kW 74

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tHe plAntIn tHe amadori testimony.Interview with lorenzo Battistini, technical Manager Amadori

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what is your view on energy efficiency from cogeneration in the light of your experiences to date?

Cogeneration is definitely one of the best technologies available today to maximise energy recovery, whatever the primary source used.In designing and sizing the cogeneration plants along with AB, Amadori has certainly applied the methodology that guarantees the maximum recovery of the thermal energy which the system inevitably produces while running. It is only with this approach that you can be sure of making the most of the possibilities that the cogeneration system allows. In the transformation of a primary energy source such as methane gas and even biogas, it is necessary to recover as much of the heat as possible - which otherwise would have been disposed of in another way - to guarantee the correct functioning of the system.

how do you view the collaboration with ab, even in terms of respect of the planning and the service activities?

AB is a partner who is easy to work with thanks to the professionalism of its operators. Amadori has chosen to collaborate with AB because its skills from a technical point of view and the planning ability of its professionals were immediately clear. However, the most important thing for us, with such complex plants like the ones which we have installed, is being able to count on an excellent after sales support. this is the only way to establish a strong partnership with the supplier, i.e. a relationship that is not exhausted in the installation of the plant, but which continues and is strengthened even after this, with constant checking of the achievement of the objectives established at the start of the project.

do you think that cogeneration and also bio can be developed further in your energy efficiency plans?

we believe that the systems that allow to make energy transformation efficient will always be a focal point of our company’s technicians. On a daily basis the cogeneration systems improve their performances and therefore maintain a record in our view, both in financial and technical terms, which up to now has not been easily matched by others. we are determined to continue choosing systems that make it possible to use all the thermal energy that the system can produce. In our supply chain, the availability of matrices capable of producing high quality biogas from biodigestion only reinforces the choices of this type of technology for the combined production of heat and electric energy with considerable benefits both in financial and environmental terms.

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ab

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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

AB Service SrlserviCe

AB Fin-solution SpAfinanCing

renewableenergy

AB Energy International GmbH

KWE Technika Energetyczna Sp. z.o.o.

AB EnergyRomania Srl

AB EnergyEspaña S.L.

AB EnergyHrvatska d.o.o.

Green House Power Netherlands BV

EPS AB Energy Canada Ltd.

AB EnergySrbija d.o.o.

AB Energy Ceská s.r.o.

AB Energy do Brasil Ltda

foreignbranChes

AB Energy (UK) Ltd.

AB EnergyDeutschland GmbH

AB Energy USA LCC

AB EnergyRussia

AB EnergyIsrael Ltd.

AB Energy France

AB Energy Turkey

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.

www.biogaschannel.com

www.cogenerationchannel.com

AB energy spAvia Caduti del lavoro, 13 25034 Orzinuovi Bs - Italyt. +39 030 94 00 100www.gruppoab.com

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