Cannon Bono Energia solutions for Pirelli in Russia
Cannon Eurasia, Cannon Bono Energia and Cannon Artes Ingegneria cooperate to supply a turn-key thermal plant —producing 75 ton/h of steam at 26 bar —for the Pirelli tyre factory of Voronezh, 500 km south of Moscow, Russia.
The project started when Pirelli, owners of VSZ (Voronezh Shina Zavod), decided to provide an internal source of heat for the vulcanising process that supplies rubber to the truck tyres factory, ending a heat supply contract with the local Voronezh thermal plant.
The strategic decision to end the purchase of saturated steam from the municipal source will guarantee a substantial and continuing money saving.
This investment was decided within a wider frame of modernisation, to make the Voronezh site the most advanced of its kind in Russia.
In 2012 the replacement of the whole production equipment was completed, installing the most advanced rubber blending technological solutions with an investment of 56 million Euro.
A new production line was inaugurated at the end of 2012, with the participation of Dimitry Manturov, Russian Federation’s Minister of Industry and Commerce, Alexander Gordeev, Governor of the Voronezh region, Sergey Victorovich Chemezov, General Manager of Russian Technologies and Marco Tronchetti Provera, President of Pirelli.
Within 2015 a further investment of 44 million Euro is foreseen, to increase the production capacity of the plant to 4 million truck tyres per year.
The turn-key thermal plant supplied by Cannon Bono Energia will be completed by the first half of 2014.
For the Pirelli Russia project Cannon Artes Ingegneria , specialised in water and waste water treatment plants, is supplying the feed water treatment equipment, composed by a reverse osmosis section and two degassing units.
Cannon Bono Energia supplies the complete thermal plant, composed by three water tube boilers —featuring a total capacity of 53 megawatts —fully integrated with the water treatment section supplied by Cannon Artes Ingegneria.
The cooperation between Cannon Bono Energia and a local Project Institute —charged with the task of aligning the project details with the stringent Russian norms to transform the space made available by Pirelli in a completely functioning thermal plant. A fundamental role in this achievement is played by Cannon Eurasia, the Moscow-based Cannon subsidiary holding a SRO (Self-Regulatory Organization) licence that allows them to sell and install turn-key plants on the whole Russian territory.
The project’s details
The saturated steam production line consists of three water tube boilers producing 25 ton/h of steam at a design pressure of 26 bar, to guarantee a steady supply to the working islands at 21 bar.
The boilers are equipped with a heat recovery system that transfers the thermal energy still present in the exhaust fumes to an heat exchanger installed on the water feeding line: this allows for an effective efficiency rate of the boilers higher than 95%, at full charge.
The thermal plant’s electronic control system, designed and built by Cannon Bono Energia, also handles the water treatment functions of the Cannon Artes Ingegneria section.
One of its most interesting features is the possibility to balance automatically the load of the three boilers in accordance with the demand of the production departments.
A further reduction of the running costs is obtained by using inverters on all the pump’s electric motors and on the fans of the boiler’s burners, and by controlling continuously the critical points of the process through a network of sensors.
The reverse osmosis group supplied by Cannon Artes Ingegneria has been designed to treat 50 ton/h of water coming from the Don river. The supply includes an in-line pre-treatment section with two filters and one disinfection unit, designed for a wide range of potential polluting substances.
The demineralisation process is engineered targeting the highest possible level of recovery (75%) while guaranteeing the water quality at a conductivity value around 20 microSiemens, required for the perfect operation of the boilers.
This solution guarantees the highest reliability in combination with low running and maintenance costs.
The presence of two parallel-operating lines ensures smooth operations also during maintenance.
For the Oxygen removal Cannon Artes Ingegneria supplies two thermo-physical deaerators able to produce 75 ton/h of degassed water. The patented Spray&Tray technology —developed internally, whose name derives from the special jets used to pulverise the incoming water and from the inner design of the tower where the thermal and phase exchange occur —allows to obtain an excellent level of extraction of O2 and CO2 from the feed water, reaching a minimum concentration of 5 ppb of O2.
PIRELLI and Cannon Bono Energia, a long history of cooperation
This Russian project reinforces a consolidated relation between Pirelli Tyre and Cannon Bono Energia, that already counts —among the latest supplies —a water tube CTD unit rated 30 ton/h of steam for the car tyres plant in Alessandria, Egypt, and another 25 ton/h CTD for the Turin factory in Italy.
The three Cannon Group companies —Cannon Eurasia, Cannon Bono Energia and Cannon Artes Ingegneria —cooperated very efficiently to win this important contract, implementing once more an internationalisation strategy that targets the diffusion of the BONO and ARTES brands in fast-growing markets, taking full advantage from the experience and the market knowledge matured from the local Cannon units operating since very many years in the Polyurethane and plastics businesses.