luciano falqui – r&d project manager - plastica alfa srl ...€¦ · an agile organizational...

Luciano Falqui – R&D Project Manager - Plastica Alfa SrlLaura Cutaia – Responsible of industrial symbiosis activities - ENEA

Since 1983 Plastica Alfa develops innovative polymer based products for watermanagement and under the constant guidance of its CEO Mario Pace, has succeeded inentering into the overseas market. Starting from 1990, thanks to Alfaidro systemproduction, Plastica Alfa has become a solid industrial reality in the global market forpipes and fittings polypropylene random processing .

An agile organizational structure, a flexible productiveorganization, a young and dynamic staff are the resources thatenabled Plastica Alfa to be present in 80 countries in the world, tostrengthen commercial relationships and penetrate newsegments of the market, maintaining the aim of Total Quality.

The continuous improvement of the productive process hasalways been the most important long‐term target in theconviction that the true priority is that of providing high qualityproducts, guaranteed in efficiency and reliability, conceivedaccording to the International Standards and manufactured withhigh‐quality materials.

In the last twenty years the production department has always been improving linesproduction and new products, also thanks to the new technologies employed: at themoment Plastica Alfa’s portfolio includes over 4400 items divided into 600 types fordifferent fields of application: irrigation, hydraulics, thermo‐hydraulics and oil&gas.

Injection moulding

In our department polymeric materials are transformedusing injection molding machine and extruders.Injection molding area covers over 4.000 m2 area and itis equipped with 34 injection molding presses atdifferent tonnage, from 90 to 830 tons continuouslyprocessing more than 2400 ton/year raw material

The extrusion area covers a 6000 m2 aea andconsists of different 12 producion lines forpolyethylene and polypropylene pipes , 1 line forMultilayers pipes (PEX‐AL‐PEX) and 1 line for coextrusion multilayers advanced pipes

Extrusion

•Market focusing•New Product development

•Renewable Energy•Carbon Capture & Conversion •Advanced Technology

•New added value products•New markets•New sectors development

•Working cost Reduction

• Energy cost reduction

• Increase production efficiency

• Environment protection

1. Global

Production Efficiency

2.New product Development

3.Innovative

Polymer Based Materials

4.Advanced Technology Development

R&D DEPARTMENT

R&D Department is constantly developing innovative products and systems for water management. Inthe last five years the attention has focused also in the production of energy from renewable sourcesand environmental protection having acquired a specific know‐how on the processes ofthermochemical conversion of biomass and processes Carbon Capture & conversion

Technological District

Plastica Alfa (AGROBIOPESCA TECHNOLOGICAL DISTRICT) plays a leading role in“BIO4BIO”, a strategic National R&D Project supported by Ministry of Education,University and Research (MIUR) in Italy . The aim of the project is the valorization ofAgroindustry residual waste biomass. BIO4BIO Project is developed in collaborationwith National Council of Research (CNR) and Chemical and Engineering Universities.Project was funded for 11.8 M€.

Potential factor of competitiveness for industrial activities

Factor of enrichment for the region

Environment protection

Renewable energy production

P.O.N. RICERCA E COMPETITIVITA' 2007‐2013 ‐ Avviso n. 713/Ric. del 29/10/2010 Titolo II ‐ "Sviluppo/Potenziamento di DAT e di LPP"

Valorizzazione biomolecolare ed energetica di biomasse residuali del settore agroindustriale ed itticoPON02_00451_3362376

WASTE BIOMASS

EnergeticValorisation

MolecularValorisation

Agroindustryprocesses

Renewable Energy

Feed – nutraceuticalapplication

Process InnovationProduct/processdiversification

Advanced process development

Advanced materials development

Reduction ofProductive Costs

Agroindustryprocesses

WASTE BIOMASS

BIO4BIOBiomolecular and Energy valorization of residual biomass from Agroindustry

making the residues of one activity available for another one

changing the nature of biomass residue: from problem to resources

developing circular economy

“Driving competitiveness through industrial symbiosis”

Starting from 2014 Plastica Alfa and AGROBIOPESCA Consortium have joined with great interest tothe Symbiosis Platform recently conceived Sicily Region (by the agreement between ENEA ‐ ItalianAgency for New Technologies, Energy and Sustainable Economic Development, and ConfindustriaSicilia, the Regional Federation of Industries.

Consorzio Innova Agro SiciliaConsorzio Ricerca Sviluppo e innovazione (CORISVI)

AGROINDUSTRY‐ SMEsMANGIMI DI PASQUALE Srl

AGRUMIGEL SrlOLEIFICIO SAN CALOGERO

PHARMACEUTIC SMEMEDIVIS Srl

RENEWABLE ENERGY – ENVIRONMENT PROTECTION – ADVANCED TECHNOLOGY DEVELOPMENT ‐ SMEs

AAT SrlPLASTICA ALFA Srl

ENVISEP SrlROMA Srl

SMEs

Agrobiopesca Technological Consortium

University of Studies of CataniaDipartimento di Scienze Chimiche (DSC)Dipartimento di Ingegneria Industriale e Meccanica (DIIM)Dipartimento di Scienze delle Produzioni Agrarie e Alimentari (DISPA)

University of Studies of PalermoDipartimento Scienze Agrarie e ForestaliCentro interdipartimentale per lo studio dell'ecologia degli ambienti costieri (CISAC)Dipartimento di Ingegneria Chimica, Gestionale, Informatica e MeccanicaDipartimento dei Sistemi Agroambientali (SAGA)BioNec

University of Studies of MessinaDipartimento di Morfologia, Biochimica, Fisiologia e Produzioni Animali (DIMOBIFIPA)

National Council of Research (CNR)Istituto per lo Studio dei Materiali Nanostrutturati (ISMN)Istituto di Chimica Biomolecolare (ICB)Istituto di Chimica e Tecnologia dei Polimeri (ICTP)Istituto per i Processi Chimico‐Fisici (IPCF)Istituto di Tecnologie Avanzate per l'Energia (ITAE)Istituto per i Sistemi Agricoli e Forestali del Mediterraneo (ISAFOM)

Regional Research ConsortiumConsorzio Regionale per la Ricerca Applicata e la Sperimentazione (CORERAS)Consorzio di Ricerca Filiera Carni (CoRFilCarni)Consorzio di Ricerca G.P. BALLATORE

OR 1 – Advanced process for biomolecular valorisation of

waste biomas

OR 2 – Renewable energy productionBiochar production Bio fuel production

OR 3 – Biomolecularvalorisation of exaust gas from energy production

processes

Biomolecular and Energy valorization of residual biomass from Agroindustry (BIO4BIO)

The plant is equipped with an extraction capacity of 40 tons of citrus per hour and technology FMC "in line" it allows to obtain juices and essential oils of the highest quality for use in the food or cosmetic.

La conservazione dei succhi avviene a temperatura controllata nelle celle aziendali presenti in situ la cui capacità sfiora i 5.000.000 di Kg.

Starting from the residual biomass of orange juiceproduction, an innovative drying process has beendeveloped. The aim is to preserve and protect mostof chemical components that are present into thebiomass such as “pectine”, an important product fornutraceutical, pharmaceutical and zootechnic feedapplications.

Sludge extrusion system patentedby Officine di Cartigliano SpA (Italy)


Waste biomass

Development of innovative process New By product

Market Diversification

SME: MANGIMI DI PASQUALESME:AGRUMIGEL

Market: orange juice production

circular economy

New Market: Pectine production New Market: Feed production

Dry system installation

Totala hour/year production (24h/gg): 8.000 h/yResidual umidity: φ=10%N° 1 DRY SYSTEM MOD. EFT 6x7 (6moduli, 7giri)Inlet: 605 kg/hUmidity inlet: 85%Umidity outlet: 10%Total water extracted: 505 kg/hTotal finalproduct: 100 kg/hThermal Energy Consumption : 499 kWT (52 m3 CH4/h, or 0,5 m3 CH4/kg driedsludge)Power consumption: 84 kWE (0,8 kWE/ kg dried sludge)


waste biomas


processes


OR 2 – Renewable energyproduction

Biochar producationBio fuel production

LIGNOCELLULOSIC BIOMASS COMPOSITION

BIOMASS

PROCESSES

OIL EXTRACTION

TECHNOLOGIES PRODUCTS

TRANS-ESTERIFICATION

FILTRATIONE BIO OIL

BIODIESEL

BIOCHEMICAL

ANAEROBIC DIGESTION

ALCOOL FERMENTATION

BIOGAS

BIOETHANOL

THERMOCHEMICALPIROLISI

GASSIFICAZIONE

COMBUSTION THERMAL ENERGY

SYNGAS/OIL

OIL / PRODUCER GAS / BIOCHAR

DISSOCIAZIONE MOLECOLARE

SYNGAS / LIQUID FUEL

AGROINDUSTRY RESIDUAL BIOMASS (Ton/Year)

Product Agrigento Palermo Trapani Enna Caltanisetta Catania Messina Ragusa Siracusa Totale

Paglie di cereali 41.388 20.866 20.866 34.992 31.590 22.759 744 46.899 32.009 252.117Residui di potatura 114.979 186.439 88.554 42.145 53.178 177.093 68.855 46.582 118.654 896.481

Vinacce 6.187 31.772 31.772 522 4.419 4.562 1.030 1.286 4.044 85.597

Sanse 29.6758 18.0600 18.060 10.941 7.300 27.000 12.042 8.940 12.324 144.342

Noccioli di frutta 2.8760 163 700 570 2.876 2.876 10.061Gusci di frutta secca 19.015 11.750 9.302 4.349 7.500 4.042 8.170 64.128

Agrumi (82%) x 27.700 x x x 88.150 2.800 x 47.190 230.153

Totale 214.1223 257.139 159.254 100.513,30 106.489 236.333 93.048 110.625 175.202 1.682.882


Waste lignocellusic biomass

Development of innovative process Energy Production

Biofuel productionBiopolymersBioChar


SMEs: Plastica Alfa SMEs: Agroindustry Consortium

Market: olive and wine production

circular economy

New Market: Energy productionNew Market: Biopolymers productionPyrolisis plant realisation

GAS CLEANING

SYNGASCOCO2H2CH4N2CxHy

SYNGAS

DRYER

Thermal Energy

Exaust gas Filtration and conditioning

WASTE/ BIOMASS

Electric Energy

CHAR

ASH

TARBIO OIL

Pyrolisis ProcessO2 Absence

T= 250°C – 700°C

CO2

WASTE

Advanced thermochemical biomass conversion process has been developed.

On line Gas Chromatographic Analysis On line – OLIVE STONE

Industrial scale pyrolysis prototype developed by Officine di Cartigliano Spa (Italy)

Analysis of waste and by‐products from manufacturing companies in Sicily (2013)

Analysis of biomass availability for energy use in Sicily, Renewable and Sustainable Energy Reviews 52 (2015) 1025–1030

Industrial scale up: 1,5 ton/h biomass pyrolysis plant (1,5 MW)

the global market for bioplastics is set to grow by 8-10% annually, increasing its value from $1bn (€0.6bn) in 2007 to $10bn (€6.4bn) by 2020.


waste biomas


processes


OR 2 – Renewable energyproduction

Biochar producationBio fuel production

GAS CLEANING

SYNGASCOCO2H2CH4N2CxHy

SYNGAS

DRYER

Thermal Energy

Exaust gas Filtration and conditioning

WASTE/ BIOMASS

Electric Energy

CHAR

ASH

TARBIO OIL

Pyrolisis ProcessO2 Absence

T= 250°C – 700°C

CO2

WASTE

Advanced thermochemical biomass conversion process has been developed.

Specific biochemical activities are focused on the carbon capture and conversion. Process of CO2conversion in microalgae will be developed. The aim is the production of algae for application innutraceutical and biofuel fields.

The aim of the project is developing a BIOREFINERY industrial configuration. The final target of the project is the integration of microalgae production plant together with other technologies or industrial plant

PHASE I _ Pilot Plant ( 1.500 liter volume ) [2015]

PHASE II _ Industrial integration of BIO4BIO prototype plant (1.000 – 2.000 m2) with Biogas plant [2016]

1) Produce microalgae for nutraceutical field2) Produce microalgae for biofuel application 3) Reduce the production cost 4) Increase the productivity of microalgae growing process step5) Develop innovative polymer based photobioreactors for microalgae production

PHASE I _ Lab Scale – Pilot Plant ( 1.500 liter volume )

PLASTICA ALFA Business Strategy on microalge production for nutraceutical products and biofuels

FIELD OF INTEREST

Polymeric Advanced materialsfor PBRs production

High value microalgae production for nutraceutical application

Integration of energy production plant with microalgae production plant to reduce the production cost

Bio polymers (??)

PHASE II _ Industrial integration of BIO4BIO prototype plant (1.000 m2) with Biogas plant

CO2

CO2 (97%)

Heating/cooling

systemWaste heatrecovery

C3 project: Carbon Capture & Conversion Upgrading Biogas/CO2 conversion

Upgrading Scheme adapted by BebraBiogas

Biomethane gas is an attractive alternative to fossil fuels. Its production is environmentally responsible, efficient and renewable. It can be mixed with natural gas and injected into the conventional gas pipeline.Supplies of fossil fuels such as coal, crude oil and natural gas are getting shorter all the time ‐effects of this phenomenon can already be seen in ever increasing energy prices. Theintroduction of sustainable renewable energies into the market is crucial; this is where biogasplays an important role. Biogas can be produced from sustainable raw material and organicwaste – locally, reliably, simply, efficiently and with environmental responsibility.

The upgrading of biogas to natural gas quality is, from the efficiency and economical aspects, avital prerequisite for its optimum utilization. Only cleaned and upgraded biogas can besuccessfully mixed with natural gas and transported through the natural gas grid for wideranging applications in industry, transportation as well as for power and heat generation.Nowadays, the biogas production and upgrading process are proven technologies; they arereliable, efficient and safe with the advantage of full integration into new and existing powerand heat generation plants.

Anaerobic Digestion is the process whereby organic matter is broken down by bacteria and enzymes in an oxygen-free environment. The organic matter is released as biogas; this is a mixture of the combustible gas methane (50-75%), carbon dioxide (25-45%), small amounts of water (2-7%) and trace gases.

Component Concentration

Methane CH4 50‐75 % Vol

Carbon dioxide CO2 25‐45 % Vol

Water H2O 2‐7 % vol

Oxygen O2 < 2% vol

Nitrogen N2 < 2% vol

Ammonia NH3 <1 % vol

Hydrogen H2 < 1% vol

Hydrogen sulphyde H2S 20 ‐20.000 ppm

Ppm: part per million; % vol: volumetric percentage

CO2


CO2 – disposal water

Development of innovative process Microalgae production


SMEs: Pharmaceutical/NutraceuticalCompanies – AAT srl – Plastica Alfa Srl

SMEs: Agroindustry Consortium

Market: biogas production

circular economy

New Market: Bio methane production

New Market: innovative productsfor nutraceutical, omega 3, advanced polymeric materials

As recommended by the new financial framework for the development of European competitivenessHorizon 2020 (€ 80 billions), Europe has to reduce the time to market of advanced technology(Phase 1 – Phase 2). For these reasons BIO4BIO is focused on the development of industrial scaleof the plant for energy production or CO2 biochemical conversion. Plastica Alfa and some othercompanies are interested to invest on this market at different level.

There is a growing market in the microalge sector. There are several players on the market:technology manufacturers, microalge producers, advanced materials producer, biofuel manufactures…..

There are a lot of sometimes different data regarding the yield of the technology.Surely there are many aspects to take into consideration that not make it easy to get to unique data:

Strain metabolism, strain selection, operative conditions, types of process, location, etc

Starting from the awareness regarding the limit of the realistic photosynthetic efficiency (PE%) and the realistic productivity of microalge close to 40 – 50 T ha-1year-1 BIO4BIO aims to develop an industrial plant to demonstrate the real feasibility of microalgae production and to obtain accurate data in term of productivity to perform a realistic industrial scale up

Why this approach?

Ingredients in medicine, pharmacy, nutraceutical and cosmetic industries, Highquality products like:Omega‐3, EPA, DHA, AA (HUFA, PUFA), beta‐1,3/1,6‐D‐glucan, astaxanthin, vitamins,minerals, carbohydrates etc.

Ingredients for animal food, aquaculture

Ingredients in Food, Beverage, Functional food, etc. Bioplastic , other bioproducts

Biodiesel «Bio Jet Fuel», Ethanol, Hydrogen,

Microalgae Market sector

+1,2 /1,7 % per year (over 950 k/y on 2025

Product Selling Price (€/kg) Status

PUFAs (DHA, EPA) 25-90 Not yet ready

Aquaculture biomass 40 – 170 Ready Fast Growing

Carotine 100-350 Ready

Astaxanthine 150 – 700 - > 1.000 Ready

Strains selection

Strains selection is developed in collaboration with NATIONAL COUNCIL OF RESEARCH (CNR) Department of Biomolecular Chemistry ‐ Catania – Italy

Strains selection

Specific combination of CO2/sunlight/nutrient have been developed to increasethe productivity of different strains selected

Astaxanthine

Phaeodactylum tricornutum

Thalassiosira pseudonana

Nannochloropsis oculata

Mixotrophic

Autotrophic

Autotrophic

Autotrophic Mixotrophic

Coccomyxa sp. Autotrophic

BIO4BIO pilot plant supplied by LGem

22‐24 April 2015 Amsterdam, The Netherlands

Harvesting step of the process

Growing 0,2‐0,6 gr/l

Pre‐concentration > 100 gr/l

Harvesting250‐300 gr/l

Harvesting step of the process

In order to maintain a constant operating temperature of the microalgae growing plant, a specific water conditioning process was developed.

PHASE II – BIOREFINERY Industrial integration of microalgae plant

A biorefinery is a facility that integrates biomass conversion processes andequipment to produce fuels, chemicals, feed, materials and energy from biomass.The objective of a biorefinery is to optimize the use of resources and minimizewastes, thereby maximizing benefits and profitability.

Biorefineries will encompass a variety of conversion processes and differentsized installations due to the range of processes – biological, chemical andthermal – that can be employed. Optimization and high efficiency are the keys tomaking biorefineries sustainable and economically viable

The cost of production of bio‐based products and, in particular, the investment needed for infrastructure and supply will have a direct bearing on their success as an alternative to fossil‐based products. An efficient biorefinery can ensure cost minimization and a cost competitive end product.

How the various processes in the conversion stage are combined will havesignificant impacts on the sustainability of bio‐based products. Throughout thebiorefinery, there is the opportunity for improved recycling of heat/energy or theregeneration of catalysts in an integrated approach, which will have an impact onthe carbon footprint of the overall process and resulting products. Newbiorefineries are often generating excess energy from waste products, which isthen fed into the grid, often lowering the net CO2 emissions from the overallprocess.

The management of industral production site on biorefinery involves different skills on engineering, mechanical, biochemical, biological fieldsIn the case of the integration of different systems, the situation is even more complex.

The industrial integration of microalgae industrial scale with differentenergy/biomass/renewable plant aims to:reuse wastewater (biofuel production)recovery CO2 (high grade CO2), recovery thermal energyOptimization processesReduce costs energy consumption

PumpingAir blubbingRecirculationLithingThermal energyStorage DryingHarvesting

AN OVERVIEW OF THE PLANT

22‐24 April 2015 Amsterdam, The Netherlands

Harvestin

g

Dewatering

Thanks for your attention

Business View session briefing:“Improved competitiveness through industrial symbiosis is often attributed to improved resource productivity. In actuality, its impacts are much broader: through industrial symbiosis, some companies have made continuous improvement while others have transformed their business model to take advantage of new opportunities. Benefits of industrial symbiosis to business and the economy include: ∙ Reducing cost: Decreasing costs associated with inputs to production and waste disposal improves profitability. ∙ Fostering innovation: Industrial symbiosis produces a demand‐pull on innovation as industry identifies novel uses for underutilized resources. The OECD and UNEP identify industrial symbiosis as supporting eco‐innovation. ∙ Increasing revenue through diversification: Creating new business opportunities to sell what used to be a ‘waste’, thus converting the cost of waste management and disposal into a revenue opportunity. ∙ Mitigating resource risk: Finding alternatives to traditional inputs, often outside the usual sector boundaries, decreases reliance on critical materials.

Barriers to implementation can be both internal (e.g., organizational) and external (e.g., market driven and regulatory):∙ Lack of knowledge and information: e.g., looking beyond company boundaries for resource applications in new sectors, or alternative inputs and technologies. ∙ Financial investments required: e.g., timing and internal targets for return on investment. ∙ Management inertia: e.g., to changing current operating procedures. ∙ Time and resource required to pursue new opportunities, particularly onerous for SMEs. ∙ Procurement challenges: e.g., specifications historically based on virgin inputs that create barriers to alternative inputs. ∙ Managing supply chains: e.g., transparency in information, aligning incentives to encourage industrial symbiosis along the supply chain. ∙ Waste legislation: Challenges in implementation of waste legislation, often variable between and within countries.”

luciano falqui – r&d project manager - plastica alfa srl ...€¦ · an agile organizational...

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