FABRIC MANUFACTURER LIMONTA
Textile industry
Textile industry
Limonta is an international group that has 10 factories and is a manufacturer of fabrics for clothing, leather goods, accessories, and footwear.
The group used an old thermal oil steam generator with an efficiency that was around 88%.
NEEDS
Industry
The textile industry has historically been facing high energy consumptions due to the washing and painting processes required in fabric production.
Both processes demand hot water with temperatures ranging from 80 to 130 Celsius degrees, produced by steam boilers and steam/water heat exchangers.
Customer
Reduce production costs and raise margins by improving the overall efficiency and simplifying ordinary management of the thermal plant.
Secondly, minimize atmospheric emissions and improve the value of the Made in Italy brand.
THE NEW THERMAL SYSTEM
We partnered up with BM Energy Studio for the design of the new thermal power plant, focusing on efficiency and emissions.
Firstly we have studied the behavior of different vector fluids and decided to use steam and feed it to steam/water heat exchangers. We ran another scenario with adding a cogeneration group but it did not come out as sustainable and applicable.
The optimal solution found that meets the 2 project goals for efficiency and emissions levels was a steam boiler coupled with a high performing burner that has low NOx emissions.
Plant's components:
The new thermal plant was a tailor-made project composed of:
- 2 steam boilers.
- 2 burner with inverter regulation systems, oxygen control, and efficiency control.
- First and second stage economizer for each boiler.
- Global Safety System GSS-72h for exemption from continuous supervision for up to 72 hours.
- Blowdown vessel and condensate collection tanks.
- Electronic system for cascade management, full automation, remote control, and waste heat recovery optimization.
RESULTS
Thanks to our technical know-how on systems for heat generation and that of BM Energy related to the design phase, we offered a new turnkey thermal power plant that delivered lower production cost emissions to the Limonta group.
The new power plant produced:
- 10 white certificates every month.
- Better efficiency raising from 88% to 96%.
- Reduction in electric consumption from 104 kW to 15 kW (-90%).
- Reduction in steam production costs by 20%.
- Lower emissions amounting to 70 mg kW / hour compared to the Italian limit of 100 mg kW / hour.
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