Bonn, Germany
Case study – Complete retrofit in the waste incineration plant in Bonn
Retrofit, modernization, performance improvementInstallation location
Challenge
Working with limited space
Conveyed material
Ash, slag
Conversion year
2019
Modules
Complete conveyor technology for boiler and FGD ash as well as slag
Result
higher system availability, more productivity and safety for daily operations
Case study
Sustainable and economic maintenance and refurbishment
For years the waste incineration plant Bonn has been relying on Loibl‘s expertise. Over a period of five years Loibl had been working together with the retrofit expert Reitz Holding GmbH & Co. KG on retrofitting the waste-fueled power station of the waste incineration plant Bonn. Besides refurbishing a slag conveying system to the hopper and various hydraulic units, the project included the manufacture, delivery and erection of several ash handling systems for boiler and FGD ash removal via trough chain conveyors and various screw conveyors, The scope of supply is completed by two ash silos through which the different ashes can be loaded onto trucks with a loading bellows and discharged.
The engineers, mechanics and site managers demonstrated their skill and working precision when they were confronted with the limited space at the Bonn location. Especially lifting into position of the two ash silos with a height of 17.5 and 19 m each was a challenge. Prior to lifting them into position Loibl mounted a steel structure with a weight of 100 tons to the outer walls of the waste-fueled power station which carries both silos weighing 15.5 and 21 tons. The steel structure is the base frame for the new building annex where the silos are installed. It must not only bear the load of both silos, but also withstand wind and snow loads and was therefore designed for heavy duty.
After its lifting into position the steel structure was provided with a roof and a wall cladding to protect the silos and Loibl’s materials handling equipment from weather. For the annex Loibl opened the existing outer wall thus creating a passage to the main site.
These refurbishment measures allowed an improved productivity of the plant. The new slag transport system provides an efficient processing operation. After the waste incineration the remaining slag drops from the grate into the slag pusher to be cooled down slowly in a water bath. After the slag pusher the slag is conveyed into the slag hopper by an apron conveyor. With one ton of waste less than 300 kg of slag will remain. About one quarter of the initial quantity of waste which can be processed for further use. For example in road construction. In addition, several tons of iron, steel and non-ferrous metals can be recovered and recycled annually. Sustainability and efficiency are not a contradiction. A higher plant availability, more productivity and safety for daily operation are guaranteed by Loibl’s retrofit measures.
Loibl’s Scope of Supply and Services
- Extensive engineering for the ready-to-use availability of refurbished components, taking measurements on site included
- Manufacture in Straubing, Bavaria
- Conveying technology for slag: slide gate valve, hydraulic, slag pusher, pan conveyor, double flap valve
- Conveying technology for boiler and FGD ash: air-cooled trough screw conveyor, slide gate valve, crusher, double flap valve, rotary feeder, trough chain conveyor, chain bucket elevator, trough screw conveyor, two-way diverter, boiler ash silo 140 m³, FGD ash silo 240 m³, truck loading bellows, moisture measurement device
- Delivery of all components
- Steel structure
- Professional disassembly of obsolete components
- Installation of all new parts
Project gallery
NO DAY WITHOUT RESIDUAL WASTE
About 1,000 tons of waste arrive at the waste-fueled power station of the waste incineration plant Bonn GmbH on workdays. Annually this is a total of 315,000 tons of waste incinerated in the power plant. The boilers are running all-day, even at weekends and on public holidays. In the waste-fueled power station in Bonn ten to twelve tons of waste are incinerated per hour. To handle these quantities, high-performance transport systems of reliable and energy-efficient operation are needed. Corrosion and wear are a frequently occurring problem for the operators of waste-fueled power stations. To avoid capacity losses caused by malfunctions and downtimes, a targeted partial refurbishment is absolutely perfect.
MINOR INTERVENTION, MAJOR EFFECT
Loibl starts every retrofit project with a professional inspection and analysis of the actual condition of the components and equipment concerned. This is followed by in-depth consultations for the presentation of specific refurbishment measures. Experienced specialists enable us to offer qualified consulting services worldwide. Then Loibl starts the engineering and manufacture implemented at the Straubing/Bavaria location. Next step is the implementation on site. To ensure a technically perfect functioning, all components of the equipment are designed and made according to the latest safety standards. Loibl’s range of retrofit work is topped off by extensive tests prior to delivery, hot and cold commissioning, maintenance work and inspections as well as professional training.
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