INTERGEN CONSOLIDATES ITS LEADERSHIP IN THE PAPER INDUSTRY
The IML Group energy division optimises the Cartiera So.Car.Pi. production system with the development and installation of a 2 MW cogeneration unit
Lomagna (Lecco), April 2016 – Intergen, the IML Group energy division, an Italian leader in the cogeneration sector, has recently installed a new 2 MW plant at the Cartiera So.Car.Pi. establishment of Villa Basilica in Lucca.
After having manufactured several cogeneration units in the paper mill district of Lucca, which alone embodies approx. 50% of the production of national paper, Intergen further strengthens its presence in the sector, with the installation of a plant equipped with a gas-powered MWM (Motoren Werke Mannheim ), TCG 2020V20 model engine, for which it has been the exclusive dealer for Italy since 1987.
The Villa Basilica industry produces rolls destined for sale to manufacturing companies (mainly within the EEC) which, from the parent roll, produces rolls of toilet paper or disposable papers. Generated almost entirely from recycled paper, the rolls are produced through the use of a Crescent Former continuous machine, which first forms the sheet, followed by pressing and finally drying. Cartiera So.Car.Pi. is one of the few Italian companies producing rolls starting from recycled paper, thus highlighting itself as a company sensitive to environmental and social issues related to the production of these types of products. Intergen cogeneration therefore represents a choice consistent with the company’s philosophy which, on one hand, allows savings in terms of consumption and, on the other hand, benefits in terms of respect for the environment.
The energy distributed, generated thanks to the Intergen cogeneration unit, is generally the best choice for all energy-intensive companies that consume large quantities of electricity and heat. The installation of the plant at the So.Car.Pi. establishment reflects the trend of an increasing number of small and medium-sized businesses towards the use of reliable technologies to make their production systems more efficient and environment friendly.
The highest consumption of electricity is concentrated in the realisation of the furnish and operation of the continuous machine and is guaranteed entirely by the new Intergen plant. The highest thermal consumption is instead due to the drying phase, which requires large quantities of steam and to the auxiliaries, which use hot water for different purposes and machining. Today, these production phases are more energy-efficient, thanks to the unique features of the MWM engines: in fact the exhaust fumes of these engines have high temperatures and thus ensure a significantly higher energy content (almost +25%) compared to competitor engines. The energy-consuming drying phase is therefore guaranteed by the 1200 kg/h steam generated at 18 bar, recovered from the engine exhaust fumes. Approx. 1,050 kWt are obtained from the cylinder liners and the oil cooling circuit, which feed a hot water distribution loop with a thermal gradient of 70-86°C. The heat recovery system relative to the use hot water has also been optimised, developing a network of points around the plant for powering different utilities and processes.
The cogeneration unit is installed inside a sound-proof container for outdoor use with a compact configuration that guarantees the containment of noise emissions below 55 dB(A) at 10 m, while the muffler, catalyst, fumes ducts, chimney and emergency dry radiators are positioned on the top of the container, thus guaranteeing optimisation of establishment spaces.
Continuous plant operation is envisioned for over 8250 hours annually. The plant has been designed to recover 100% of the steam and between 75% and 100% of the hot water, produced by the cogenerating unit, with total yields of the unit expected between 74% and 80%.
