Innovation and sustainability: Garioni Naval, heat recovery boilers in the paper industry

author: Svecom-P.E. and Garioni Naval

Industry Insight by:

SVECOM – P.E. SRL

Svecom-P.E. has been building customized solutions for the winding and unwinding of reel material since 1954. Thanks to the know-how acquired in metalworking, in September 2015 Svecom-P.E. acquires Garioni Naval brand, a historic brand that creates industrial and naval heating systems. Consequently, the manufacturing area, part of the commercial network and customer service are transferred to the Svecom-P.E. headquarters in Montecchio Maggiore (Vicenza).

Genesis of the project and preliminary study

Today, Svecom-P.E. makes the know-how acquired over the years in the paper and tissue sector available also for the production of Garioni Naval heating systems.
The paper industry is constantly evolving, driven by the search for more efficient and sustainable solutions.
It is in this context that the project emerges for an important company in the paper sector based in Lucca (Italy): a recovery steam generator with water tubes, in compact, modular design with finned tubes. The project came to life in December 2022, when the first study was launched to develop a system capable of recovering and exploiting the heat coming from exhaust fumes. This ambitious goal was translated, after a careful analysis, into a solid and innovative commercial proposal.

Sustainability and environmental impact

A fundamental aspect of the project is its contribution to the sustainable ecosystem:

  • By using this type of solution, CO2 emissions are drastically reduced: the heat recovery boiler is in fact designed to recover waste heat without the use of non-renewable fossil fuels.
  • A large part of the water is collected from the condensed steam and is pumped at high temperature to conserve as much heat as possible, minimizing losses to the atmosphere.
  • The project is in line with the goals of reducing environmental impact. Considering that the plant is active 24 hours a day, we are talking about approximately 12,000 tonnes of CO2 saved every year. A fossil fuel boiler of the same power would emit around 1500 kg of CO2 into the atmosphere per every hour of operation and would consume around 6 million Nm3/h of gas per year.

Technological innovation

Steam generators are traditional products historically available in many different forms: an uncommon peculiarity of this creation is its modularity, which facilitates transport on site and any future expansions. The product is highly customizable, reflecting the increasing demand for tailor-made solutions in the paper industry. In recent years, between the end of 2022 and the first half of 2023, 4-5 similar projects have been advanced, each characterized by unique design specifications. One of the most notable aspects of the project is the completion time: just four months, including ASME certification. This speed of execution represents a successfully overcome challenge, considering that similar projects generally require more time. The extraordinary performance was achieved thanks to an efficient organization and the adoption of advanced methodologies.

 

 Innovative heating systems, careful about consumption, energy saving and respect for the environment  

Operation and technology

Customization responds to specific needs:

  • Maximize energy recovery without consuming fossil fuel.
  • Produce more than 9.5 tons/h of steam at 16bar for a power of over 6800 kW.
  • Optimize the spaces and integrate the system with the other machinery of the plant from a mechanical, electrical and electronic point of view. For these reasons, the heat recovery boiler operates with cutting-edge technology:
  • The water tube type steam generator is characterized by a compact and modular design, with the use of finned tubes and can work with a pressure of 20 barg at a temperature of 205 °C.
  • On the one hand, maximum energy recovery from exhaust fumes is guaranteed, maximizing the efficiency of the process; on the other hand transport, installation and possible future expansions are facilitated.
  • The control system is electronic and can be managed remotely: it is connected to a network with the other components of the system, allowing the user to remotely supervise the operating parameters, modify their values and, possibly, make changes to the software.

Conclusions

The project represents Garioni Naval’s entry into the paper industry, combining technological innovation, energy efficiency and environmental sustainability. The company offers numerous other solutions such as, for example, combined water tube steam generators with steam recovery function (coming from turbo gas or cogeneration) and with burner or fire tube steam generators with burner, which can be ASME, PED, IACS, TSSA and EAC certified. The experience and expertise of SVECOM-P.E. in the sector have played a fundamental role in the success of this project: the mission, vision and corporate values that have always distinguished the company have made it possible to expand the Svecom-P.E. product range in the paper industry sector.

 

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