Half of the energy used comes from cogeneration and photovoltaic systems

Companies in the ceramic industry consume a very high amount of energy, and mainly use methane gas for the firing and drying stages; they also use electrical energy for running systems such as grinding and glazing systems, as well as offices, and for other purposes. 
Aware of the impact the supply and production chain has on the environment, for some years now, companies in the sector have been working on a green revolution, using part of their roofs for the installation of photovoltaic panels, with the aim of increasing self-production of electricity and reducing CO2 emissions.
In the survey conducted by Confindustria Ceramica in December 2022, 19 ceramic tile, sanitary ware and brick manufacturers have installed 33 photovoltaic systems, with a peak production capacity of 28.807 (kWp) and an average annual production of 33,128,602 kWh. This last figure was obtained based on the daily exposure typical of the North of Italy, where the majority of companies in the sector are concentrated. On average, the plants installed on buildings produce around 1150 kWh of energy per year per kW installed in the North of Italy. 
The same survey also indicated the number of plants that the companies will be implementing during 2023. Twelve companies are aiming to install 25 systems, with a production capacity of 34,582 kWp, and annual production estimated at 39,769,300 kWh: in a single year, 120% more capacity will be installed compared to the amount installed in the last 5 years, increasing from 28,807 to 63,389 kWp. This is an important sign, indicative that companies in the sector are speeding up the amount of self-produced electrical energy.

The ceramic sector, which has always endeavoured to improve the efficiency of its manufacturing processes, has also implemented cogeneration plants, which make it possible to produce high-efficiency thermal energy as well as electrical energy. A cogeneration plant uses methane gas to run an endothermic engine or a turbine used to produce electrical energy. The thermal energy produced, and also the energy dispersed, is directly channelled into the industrial thermal machines, enabling the saving of huge amounts of methane gas and thus reducing the amount of carbon dioxide associated with the manufacturing process. There are more than 30 cogeneration plants in the ceramic district, producing a total of more than 800 GWh of electrical energy a year.
During 2022, 45% of energy needs were covered by cogeneration systems, and 1.5% by photovoltaic panels. In 2023, the percentage of self-produced electrical energy is expected to rise to 48.5% of the total consumed; 45.5% will be self-produced using cogeneration systems and 3% by photovoltaic systems, a rise of an impressive 53% compared to the previous year. 

(Article by Sara Seghedoni, pubblished in CER il giornale della ceramica no. 398 - march/april 2023)