Hybrid Energy Control Solution for a Cement Factory in Ibiza, Spain

ComAp supported Amara NZero, an engineering company and commercial distributor dedicated to sustainable energy and the energy transition, in delivering an integrated power control solution for a cement factory located in Ibiza, part of Spain’s Balearic Islands. Amara NZero’s activities are built around decarbonisation, electrification, and energy efficiency through digitalisation, with experience across photovoltaics, wind power, electrical networks, and telecommunications. The project involved an on-grid hybrid installation combining diesel gen-sets, photovoltaic (PV) generation, and a battery energy storage system (BESS), all of which needed to operate under a single, coordinated control architecture.

The primary challenge was the integration of multiple energy sources within one power plant. Although Amara NZero had strong experience with PV and BESS, the project represented their most complex challenge to date in terms of diesel and gen-set coordination. In the original configuration, some loads were supplied directly by individual gen-sets, resulting in operating times of more than ten hours per day per unit. This led to unnecessary fuel consumption, higher maintenance costs, and limited flexibility in how energy resources were utilised.

The hybrid system included 600 kW of photovoltaic generation and a battery energy storage system consisting of five batteries providing a total of 1 MWh of storage capacity, including charging and discharging capability, deployed alongside two diesel gen-sets and the utility grid. To manage this complexity, ComAp delivered a distributed energy management solution that connected all loads to a common busbar, enabling optimal coordination between generation sources and storage. 

Control panels were supplied for the mains incomer using the InteliMains 1010 controllers, while the InteliNeo 6000 controller was deployed for advanced PV and BESS control. Each diesel gen-set was upgraded with an InteliGen 500 G2 controller to enable reliable parallel operation. The solution also included two 10-inch Panel PCs for local monitoring and control, two complete control cabinets, and approximately 80 hours of commissioning carried out over three site visits. In parallel, Amara NZero implemented modifications to the mains switchboard to integrate the required motorised circuit breakers.

Following commissioning, the site can now operate with minimal grid capacity while maximising the use of renewable energy. Generator runtime has been reduced by up to five hours per day per gen-set in worst-case scenarios, with an expected reduction of around two hours per day during the summer months. This delivers lower fuel consumption, reduced maintenance requirements, and improved overall efficiency.