Solar Boiler (Industrial Heat)
Design, fabrication and supply of modular systems for a centralized solar thermal plant.
📍Bari Plant (Italy)
Description
Project
Absolicon Solar Collector AB entrusted CADE with the engineering, fabrication, and complete supply of the Solar Boiler system for its industrial solar thermal plant in Bari (Italy).
The project involved the mechanical, electrical, and control design, the manufacture of fully equipped modular skids, their integration inside customized technical containers, and the turnkey delivery to the final site in Italy.
Each skid —a prefabricated modular unit— integrates pumps, valves, heat exchangers, instrumentation, and control systems, all engineered under the highest European standards of quality, safety, and energy efficiency.
Executed under an EPC (Engineering, Procurement & Construction) approach, the project was designed and built according to PED 2014/68/EU, Machinery Directive 2006/42/CE, and EN 13445 / EN 13480 standards, ensuring a fully compliant and operational solution ready for industrial use.
Design pressure
Steel structure weight
Components installed
The
Challenge
The main challenge was to design and build a centralized solar thermal system capable of handling heat transfer fluids at up to 180 °C and 20 bar, integrating multiple interdependent subsystems for steam generation, thermal storage, and water feed.
The complexity of the project required:
The design and manufacture of six independent skids (main circuit, TES A/B, steam generation, steam integration, and feedwater system).
Integration into two 40-foot customized containers, equipped with insulation, sliding glass panels, and a 13–15 kW air-conditioning system for temperature control.
Tight coordination of engineering, procurement, and fabrication within a total schedule of 17 weeks, maintaining full traceability of materials, instrumentation, and CE documentation.
Ensuring complete electrical and control compatibility across distributed systems, using a Siemens PLC-based control architecture (master/remote configuration).
CADE faced this challenge through its modular EPC methodology, combining multidisciplinary engineering, international procurement management, and in-house fabrication — all in close collaboration with Absolicon’s technical teams in Sweden and Italy.
CADE delivered a fully integrated solution based on modular skids, preassembled and tested in its own facilities before shipping to the final site in Bari.
Detailed Engineering
Full development of technical documentation: P&IDs, 3D models, structural and stress calculations, thermal analysis, bill of materials, and electrical & I&C documentation.Fabrication of Six Modular Subsystems
Skid 1: Main solar circuit
Skid 2–3: TES subsystems (A and B)
Skid 4: Steam generation system
Skid 5: Steam integration unit
Skid 6: Feedwater system
Over 2,500 m of industrial piping and 35 tons of steel structures were fabricated, incorporating 1,000+ components and instruments, all painted under ISO 12944 C3 system (epoxy primer + PPG Sigmadur 550H polyurethane top coat).
Containerized Integration
Two 40-foot HC containers were transformed into fully equipped technical rooms, featuring thermal insulation, power sockets, lighting, climate control, and flanged terminal connections for plug-and-play installation.Automation and Control
Complete design and supply of the electrical and control system, based on Siemens PLC technology. All wiring diagrams, signal lists, and interconnection designs were developed by CADE. Software logic was implemented in collaboration with Absolicon.Testing and Certification
The project included FAT testing, pressure and leakage tests, CE marking, 3.1 material certificates, WPS documentation, and a full quality dossier. All skids were delivered with operation and maintenance manuals compliant with the Machinery Directive.
Solución
CADE
Resultados
The Solar Boiler (Industrial Heat) system is now the operational core of an innovative and sustainable solar thermal plant, delivering clean industrial steam through concentrated solar energy.
Key results achieved:
Full EPC execution completed within 17 weeks, from purchase order to delivery in Bari (DDP Incoterms).
Plug & play modular design, minimizing on-site installation time and cost.
High thermal efficiency and reliability, with automated control and redundant safety systems.
Full compliance with European directives (PED, CE, EN, ISO).
Efficient international coordination, integrating Spanish engineering, Swedish technology, and Italian deployment.
This project highlights CADE’s expertise in industrial solar thermal EPC projects, merging engineering precision, modular execution, and international project delivery under demanding technical standards.
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