AB FORCOOPERATIVA SPERANZA

AN INTERESTING EXPERIENCE IN THE BIO-COGENERATION FIELD AT THE SERVICE OF

AGRICULTURAL COMPANIES

AB | Case History

ThE AGRICulTuRAl ENTREPRENEuR BECOmES “ENERGY PROduCER” ThANkS TOT hE VAlORISATION OF BIOGASThe growing attention of the agricultural world towards bio-cogeneration is a positive fact that highlights the evolution of the sectors’ entrepreneurship. The valorisation of biogas is, in fact, an important profit opportunity as demonstrated by the growing number of systems installed in agricultural companies and the information campaign aimed at revealing product culture and process technology.An opportunity that has recently seen the benefits also at legislative level strengthen: the L.D. “Sviluppo” (Development) 1141 (approved on 1st July 2009) has increased the important incentives to the production of electric energy from biogas, with a systems power. The fully comprehensive tariff is recognised (incentive + electric energy produced) equal to 28 Ecent per kWh inserted in the electric network, decisively more remunerative compared to the average incentives of the European Community that is around 18 ccent.The ecoincentives allow paying off a biogas cogeneration system in a particularly short time, to then start obtaining significant profits from a very effective investment, both at entrepreneurial level and as protection of the environment.Also proved that the matter requests clear and circumstantial information, such to make clear how to obtain the maximum benefits from an investment of this kind. In particular, it is fundamental that the agricultural entrepreneur understands the various production process phases of the biogas and of the energy valorisation of the same, giving greater attention to the choice of technological components able to positively affect the production performance of the entire system. The cogeneration unit certainly stands out. If it is true that the anaerobic digestion to produce biogas happens in the fermenters, it is also true that the energy yield and the total economical efficiency of the system depend on the quality and the technological solutions characterising the cogeneration unit. A significant example of the advantages of bio-cogeneration is the system operational since 2008 at the Cooperativa Speranza of Candiolo, in the province of Turin.The most forward-looking agricultural company looks at cogeneration and finds AB Energy the best partner in the sector. An evident demonstration of this added value, are the results of the cogeneration systems designed, realised and installed by AB Energy, the company of the AB Group of Orzinuovi (Brescia), leader in Italy within the power range that goes from 100 to 10.000 kWe. In recent years, the Group has widened its activity with the development of the BIO line, studied to add value to the anaerobic digestion biogas energy. An orientation immediately appreciated by the market, as proven by the growth in job orders.The know-how, result of the AB experience throughout the national territory and the over 230 systems installed, represent a solid base for reliability to guarantee the agricultural entrepreneur, turning “producer of energy”, the hoped for economical earnings.The offer of AB is preferred because, as also confirmed in the case of the Cooperativa Speranza of Candiolo, the after-sales assistance, operational 24/24, 365 days per year, has a strategic role. The success verified by AB Energy and by the systems realised and installed, is the most significant and concrete demonstration that electricity can be produced from agricultural and zootechnics waste and therefore profit but, most of all, it states that only by investing in evolved cogenerative technology one is certain that not even one euro... “goes up in smoke!”

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ThE AIm OF COOPERATIVA SPERANZA: ACTIVATE A NATuRAl CYClE ThAT JOINS ECONOmICAlPROFIT ANd ATTENTION TO ThE ENVIRONmENT.

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Cooperativa Speranza mainly works in the zootechnics sector and sells its products directly to the public. The cooperative joins five companies that can draw from the technological resources and machines in common.

In fact, the bio-cogeneration is based on a natural cycle. The farmers of the Cooperativa proposed their idea of a system to the Municipal Administration of Candiolo in January 2006.The work started in the Summer of 2007 and the system was activated in April 2008: it produces eight million kilowatt (electric energy) per year and the same kilocalories (thermal energy). It uses manure and animal slur, the waste of vegetable products and a part of cut up corn. Everything is inserted inside digesters where the decomposition of the organic material produces methane. At the end of this cycle the biogas becomes fuel for the cogenerator, producing electric energy and heat; the remaining biomass is separated forming a compost and a mineral fertiliser that returns to the field, exactly where the cycle had started.

The Cooperativa has developed various experiences, abroad also, verifying the advantages of the bio-cogeneration. The decision to have its own system of this type reconciled the entrepreneurial profit with the attention the Cooperativa has for the environment.

The system does not produce emissions in the air in that the organic substance is digested in anaerobic environment and is therefore. 

The whole transmission process is constantly monitored through software and control unit.

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A SYSTEm OPERATIONAl 365 dAYS PER YEAR ThAT CONSTANTlY GENERATES VAluE FROm ZOOTEChNICS ANd AGRICulTuRAl wASTE.

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Cooperativa Speranza system features:

ECOmAx10 BIOFuel consumption 521 Nm3/h

Introduced power 5645 kW

Electric power 1063 kW

Electric efficiency 40,8 %

NATuRE ANd TEChNOlOGYTOGEThER TO OBTAIN ImPORTANT AdVANTAGES. The anaerobic digestion is a natural process that, is correctly handled, determines a continuous methanisation able to power the cogeneration systems.The process is simple and rational, applicable within the organisation of agricultural and zootechnical companies, without requirement substantial changes in the activities.

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The anaerobic digestionIs a conversion process of biochemical type that happens without oxygen and that consists in the demolition, through micro-organisms, of complex organic substances (fats, protein, glucides) contained in vegetables and in products originating from animals.The biogas produced is usually made of approximately 50/70% methane and the remaining part of CO2 and other components.

Fermentative bacteria

hyperacid bacteria

hydrolytic phase

hyperacidic phase

Simple organic substances (NH3, CO2, H2)

Biodegradation

Complex organic substances

Alcohol, organic acid, ketons

methanogenic bacteria

methanisation

Bio

gas

(CH

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O2,

H2,

N2)

Res

idue

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gani

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* The temperature influences the entire process

Advantages• ElECTRIC ANd ThERmAl ENERGY PROduCTION ThROuGh ThE INSTAllATION OF A COGENERATION SYSTEm• SIGNIFICANT REduCTION OF OdOuRS ANd POlluTING EmISSIONS• CO2 EmISSION ANd CONSumPTION BAlANCE PRACTICAllY Null• REduCTION OF PAThOGEN GERmS• uSE OF dIGESTEd mud TO CONdITION SOIl

È inutile che leggiate questo testo: non è quello che vedrete sulla pagina stampata. Si schizza coi pennarelli quella che sarà poi una foto, ma non si può “schizzare” un testo pubblicitario così, “tanto per rendere l’idea”. Un testo pubblicitario è un complesso e delicato incastro di documentazione di prodotto, comunicazione, persuasione e creatività. Se poi volete, possiamo metterci anche un po’ di bella scrittura. Tutte cose che sarebbe un po’ riduttivo “schizzare”.Abbiamo reso l’idea?

È inutile che leggiate questo testo: non è quello che vedrete sulla pagina stampata. Si schizza coi pennarelli quella che sarà poi una foto, ma non si

può “schizzare” un testo pubblicitario così, “tanto per rendere l’idea”. Un testo pubblicitario è un complesso e delicato incastro di documentazione

di prodotto, comunicazione, persuasione e creatività. Se poi volete, possiamo metterci anche un po’ di bella scrittura. Tutte cose che sarebbe

un po’ riduttivo “schizzare”.Abbiamo reso l’idea?

È inutile che leggiate questo testo: non è quello che vedrete sulla pagina stampata. Si schizza coi pennarelli quella che sarà poi una foto, ma non si può “schizzare” un testo pubblicitario così, “tanto per rendere l’idea”. Un testo pubblicitario è un complesso e delicato incastro di documentazione di prodotto, comunicazione, persuasione e creatività. Se poi volete, possiamo metterci anche un po’ di bella scrittura. Tutte cose che sarebbe un po’ riduttivo “schizzare”.Abbiamo reso l’idea?

CuRRENT SITuATION NEw BOdIES

BACkFlOw STORAGE

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ElECTRIC ENERGY

ThERmAl ENERGY

ENER

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BIOGASEFFluENT

ECOmAx® 10BIO

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ThE ChARACTERISING ElEmENTS OF ThE AB ENERGY SYSTEm FOR ThE COOPERATIVA SPERANZA .

TIMELINE WORK

40

DesigningPre-manufacture in workshopRealisation building worksAssemblyStart-upsContinuous exercise

October November December January February March April May JuneMonth Week 41 42 43 44 45 46 47 48 49 50 51 52 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

The Cooperativa Speranza, thanks to the investment made, will produce on average 4.200.000 m3 of biogas per year, generating electric energy from a 990 kwe cogeneration unit for a total of over 8.400.000 kwh and thermal energy at a starting power of 588 kwt, that will be increased following installation, already arranged, of a boiler for achieving a total production of over 6.780.000 kw.

The former will be totally transferred to the electricity network, with the consequent remuneration of the incentive tariffs, the later will be self-consumed as hot water and can be supplied to the utilities present in the surrounding area.

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Yerly functioning 8.600 h

Functioning turns 168 h/set. 7 g/set.

Average annual production of biogas 4.200.000 m3

Yearly production of electric energy 8.400.000 kwh

Yearly production of thermal energy 6.780.000 kwh

Cogeneration unit power 990 kw

CO2 emissions avoided 5.670 t/a

Furthermore, by introducing energy in the network produced by renewable sources, the system allows to avoid a large amount of CO2 emissions (approx. 5.670 t/a), thanks to the use of fossil fuel.For the companies being part of the Cooperativa Speranza, the decision to realise a biogas system is based on a particular sensitiveness towards the environment, a winning choice also from an economical point of view.

ThE SYSTEmS’ EFFICIENCY STATEd BY ThOSE uSING IT.Interview to Carlo Vanzetti, partner of the Cooperativa Speranza and president of the local section of Coldiretti (Provincial Farmers’ Federation).

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what prompt you to invest in a system of this type?“Our system is a clear example of differentiation of the agricultural work and of multifunctionality. Cogeneration, as well as being an excellent solution from an environmental point of view, thanks to the production of clean energy, offers economical advantages through the sale of electricity current. Furthermore, the biogas obtained is a balance of emission and consumption of carbon dioxide, practically null”.

what is your degree of satisfaction today?“We are very satisfied. It has been an important investment for our cooperative, with a fairly high risk percentage. However, the system has been working perfectly for over a year, revs at maximum power, with significant numbers”.

what biomasses does your system use?“The structure mainly uses company subproducts which manure and slur; as well as corn, grass in silos and cut up. The biodigestor is fed with 600 tons of material every day. Cut ups and other biomasses of agricultural origin, together with zootechnics slur, introduced in large fermentation tanks, following an anaerobic digestion process, originate the biogas that powers the cogeneration system. In just under two months from the organic material, the digesters extract methane used to power a motor that produces electric and thermal energy. At the end of the cycle, a digested residue remains that can be used as fertiliser for the agricultural land”.

why did you turn to AB Energy?“AB Energy is a company that we believe to be serious and professional, as it has demonstrated. With its project, it has optimised our choices being a company present and active on the territory”.

In what has it excelled your expectations?“We breed milk cows, therefore we are used to dedicating particular attention to handling effluents: we consider the system is comparable to a cow with a cement tummy, that produces gas instead of milk and, if handled with care, preserving the biomass in anaerobic environment, it produces yields higher than the highest expectations. This is also thanks to the assistance received from AB for the routine and extraordinary maintenance on the installed system”.

how important is cogeneration in a global context of a system for the production of biogas?“it is fundamental, even if often in our sector more attention is given to the “biological” part of the system, to the bio-digester and to the production of gas. Instead, it would be opportune to concentrate on the cogeneration technologies, which determine the quality of the energy produced and, consequently, the profitability of the entire project. This is why we turned to the experience of AB Energy, realised in a system with very high energy efficiency and, at the same time, completely reliable”.

what advantages do you draw at entrepreneurial level?“This appliance allows the associated companies to close the factory, adding value to all company productions. The biodigestor will give work to two sons of farmers, in addition to the seasonal staff and the entire activity around it. This system is a clear example of differentiation of the agricultural work and of multifunctionality. Cogeneration, as well as being an excellent solution from an environmental point of view, thanks to the production of clean energy, offers economical advantages through the sale of electric current. Biogas is ideal for reaching energy autonomy and it contributes in decreasing the atmospheric pollution.It must also be remembered that the Cancer Research Institute of Candiolo and other industrial installations are just a few hundred of metres away from our reality; we are considering eventual solutions for diffusing excess heat that can have positive results for the community”.

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Cogeneration has resulted a winning choice in other sectors also, industrial and not: food, chemical-pharmaceutical, textile, plastic, paper, bricks, etc.

Those who have chosen AB Energy:Amadori, Assolac, Buitoni, Centrale del latte di Firenze, Cotonificio Albini, Fatro, Felli Color, Gruppo Cremonini, La Farge, Martini & Rossi, Nestlè, Olimpias Benetton, Pastificio Ferrara, Pastificio Rummo, Pfizer, Polynt, Wienerberger, etc.

THEGRUPPO AB.Established and directed by Angelo Baronchelli, the AB Industrial Group has been operating for over 30 years in the field of cogeneration and the promotion of energy from renewable sources.Today the Gruppo AB counts 12 operating companies and over 450 employees.Being outright Italian market leader has also favoured its growth abroad.The Gruppo AB has designed and manufactured over 500 “turnkey” cogeneration plants. AB plants stand out for their high performance, modularity, compact design and ease of transport – all features that fully cater to the energy requirements of the different customer companies.The Gruppo AB has extended its product range with the BIO line, designed to promote energy from biogas.For its customers, the Gruppo AB is a single interlocutor, able to take care of every aspect of plant engineering. Through its Group companies in fact, it places at disposal all the technical know-how required for plant design, manufacture, installation and running, implementing the entire project, from building to start-up through to a maintenance service that covers the complete life cycle of the installation.The Gruppo AB has recently undertaken an expansion process, which has also taken it abroad into those Euro-pean countries where cogeneration is acquiring an increasingly more strategic role. After launching onto the Spanish market, with offices in Madrid and Barcelona, the Group is now also wagering on the east-European market and, in 2009, opened a subsidiary in Bucharest. In April, 2010, AB acquired the majority share of KWE Technika Energetyczna, local distributor and service partner for GE Jenbacher motors in Poland.AB and GE partnership got even stronger in 2011, with the opening of two new AB branches in Serbia and Croa-zia.

mONITORING SYSTEm

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AB Energy SpAVia Caduti del Lavoro, 13 25034 Orzinuovi BS - ItalyT. +39 030 94 00 100www.gruppoab.com