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.

0 bar

Design pressure

0 t

Steel structure weight

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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.

  1. 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.

  2. 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).

  3. 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.

  4. 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.

  5. 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.

Absolicon video on Vimeo

Albacete

Parque Científico y Tecnológico

Paseo de la Innovación 3, 02006 Albacete – España

Tel. +34 967 19 01 72

Madrid

C/Raimundo Fernández Villaverde, 53 (Entreplanta)

28020

Madrid – España

Albacete

Parque Científico y Tecnológico

Paseo de la Innovación 3, 02006 Albacete – España

Tel. +34 967 19 01 72

Madrid

C/Raimundo Fernández Villaverde, 53 (Entreplanta)

28020

Madrid – España

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