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.

4

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.

5

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.

6

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

7

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

8

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.

9

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.

10

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

11

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.

12

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

13

≤

ECOMAx®

PLANTS

14

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

16

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)

18

AB

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LDIN

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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

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.

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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