Cogeneration Supporting the Energy Transition in the Italian Ceramic Tile Industry

Abstract

Ceramic tile production is an industrial process where energy efficiency management is crucial, given the high amount of energy (electrical and thermal) required by the production cycle. This study presents the preliminary results of a research project aimed at defining the benefits of using combined heat and power (CHP) systems in the ceramic sector. Data collected from ten CHP installations allowed us to outline the average characteristics of prime movers, and to quantify the contribution of CHP thermal energy supporting the dryer process. The electric size of the installed CHP units resulted in being between 3.4 MW and 4.9 MW, with an average value of 4 MW. Data revealed that when the goal is to maximize the generation of electricity for self-consumption, internal combustion engines are the preferred choice due to higher conversion efficiency. In contrast, gas turbines allowed us to minimize the consumption of natural gas input to the spray dryer. Indeed, the fraction of the dryer thermal demand (between 600–950 kcal/kgH2O), covered by CHP discharged heat, is strictly dependent on the type of prime mover installed: lower values, in the range of 30–45%, are characteristic of combustion engines, whereas the use of gas turbines can contribute up to 77% of the process’s total consumption.

Impact of Energy Monitoring and Management Systems on the Implementation and Planning of Energy Performance Improved Actions: An Empirical Analysis Based on Energy Audits in Italy

“…The analysis of both implemented EPIAs (EPIAs, starting from here) and planned EPIAs covers, in addition to general EPIAs, also measures in technical intervention categories, such as pressure systems, heat recovery systems and thermal plants, inverters and other electrical machines and installations, transport, heating and cooling, and building envelope [32]. Measures in the categories of cogeneration and trigeneration and production from renewable sources were excluded from the analysis since they are associated with savings of primary energy [33]. In different NACE sectors, the number of EPIAs in enterprises that have an ISO 50001 certification and a monitoring system and are defined as SMEs is shown in Figure 3.…”

The Use of Prospect Theory for Energy Sustainable Industry 4.0

“…These alternatives were presented by the UM IAC experts' energy assessment of the plant's manufacturing processes according to energy efficiency measures and then were recommended in the energy audit report. Energy audits generally allow for analyzing energy flows for the purpose of energy savings to make industrial technology or production processes more efficient [104][105][106][107]. Based on their analysis of energy collection data and the technology recommendations outlined in the energy report, the experts have selected or defined assessment criteria and sub-criteria as presented in Tables 4 and 5.…”

Chemically Recuperated Gas Turbines for Offshore Platform: Energy and Environmental Performance

“…The improvement of energy efficiency can meet the emission targets and decrease fuel consumption [9]. Simple cycle GTEs have a significant potential margin for energy saving and carbon dioxide emission reduction.…”