Category: News

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Steinmüller Babcock Environment and Wallstein increase energy efficiency at RZR Herten

Gummersbach, 21th June 2018. Steinmüller Babcock Environment GmbH based in Gummersbach and Wallstein GmbH from Recklinghausen have received orders from AGR Abfallentsorgungs-Gesellschaft Ruhrgebiet mbH and its subsidiary RZR II Herten GmbH for the construction of a heat recovery system for the four municipal waste incineration lines of the RZR Herten waste power plant.

RZR Herten is already very energy-efficient and uses the energy from municipal and commercial waste to generate electricity and district heating. Each of the four municipal waste incineration lines will be equipped with an additional heat exchanger on the flue gas side in order to make efficient use of energy that was previously unusable. The residual heat recovered in this way is fed into the district heating grid “Fernwärmeschiene Ruhr”. The new system increases both the efficiency of the entire plant and operational flexibility.

While Wallstein Ingenieur GmbH as consortium leader is responsible for the process engineering system guarantee and delivery of the corrosion-resistant heat exchangers, the scope of supply and services of Steinmüller Babcock Environment GmbH includes the remaining system components, their system integration and complete assembly. The project is scheduled for completion by December 2018. The scheduled revision phases of the four municipal waste incineration lines will be used for installation.

Picture: Heat exchangers (blue) are integrated into the four municipal waste incineration lines, which transfer the still usable waste heat to the district heating grid “Fernwärmeschiene Ruhr”. Graphic: Steinmüller Babcock Environment GmbH

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Steinmüller Babcock Environment erhält Auftrag für Energy from Waste Anlage in Feixi/China

Gummersbach, 7. Dezember 2017. Die Steinmüller Babcock Environment GmbH mit Sitz in Gummersbach, Deutschland ist Technologielieferant und Lieferant von Schlüsselkomponenten beim Neubau der vier Müllverbrennungslinien für die thermische Abfallverwertungsanlage Feixi in China. Die Stadt Feixi gehört zu Hefei, der Hauptstadt der chinesischen Provinz Anhui mit960.000 Einwohnern. Das Projekt ist für die Region auf Grund des rasant steigenden Müllaufkommens von besonderer Bedeutung.

Der Kunde ist Zhejiang FEIDA Science & Technology Development im Auftrag der China Energy Conservation und Environmental Protection Company (CECEP).Wegen der guten Erfahrungen mit der Technologie in anderen Projekten entschied sich CECEP für die moderne und leistungsstarke Rosttechnologie von Steinmüller Babcock Environment sowie deren lokalen Partner. In den Jahren 2011 und 2013 wurde bereits je ein Auftrag für zwei Müllverbrennungsanlagen mit jeweils 500 Tonnen Abfalldurchsatz pro Tag in der Stadt Hefei an Steinmüller Babcock Environment vergeben.

Die neue Anlage in Feixi wird ebenfalls für einen Abfalldurchsatz von 4 x 500 Tonnen ausgelegt sein. Der Vertrag wurde im November unterzeichnet.

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Steinmüller Babcock Environment builds waste treatment centre in San Sebastian

The capital of the province of Gipuzkoa in Basque. The contracting authority is a Spanish project company led by Urbaser S.A.. The project company is commissioned by the local waste collector Gipuzkoako Hondakinen Kudeaketa SA to finance, construct and operate the waste treatment centre. Steinmüller Babcock Environment as the leader of the general contractor consortium will coordinate the planning, design, procurement, erection and commissioning of the complete complex and will erect the turnkey thermal waste treatment plant.

The concept of the waste treatment plant includes a mechanical-biological treatment stage as well as two waste incineration lines with an annual capacity of 200,000 tonnes of municipal waste. The energy generated is enough to provide electrical power to more than 45,000 households. After completion in 2019, the plant will be one of the cleanest waste treatment plants in the world. This is achieved by a three-stage flue gas cleaning concept. In the first stage, sulphur dioxide and other acidic gases are separated by means of a dry sorption process based on bicarbonate. A second stage eliminates nitrogen oxides by the use of SCR catalysts. The third stage reduces the remaining acidic pollutants as well as dioxins and furans to a minimum via a lime hydrate-based sorption process.

The mechanical-biological treatment and the thermal utilisation will replace the landfill of the waste in the currently used landfill Lapatx. The investment volume of the waste treatment centre is € 217 million, the total project value including financing and 32-year operation is about € 770 million. More information at www.steinmueller-babcock.com

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EfW plant in Delfzijl to be expanded by a 3rd waste incineration line

In Delfzijl (Netherlands) to the traditional Gummersbach company Steinmüller Babcock Environment (SBEng). The scope of the SBEng contract includes the planning and construction of a boiler including a combustion grate and ancillary facilities. Installation will begin in June 2017 with completion scheduled for only 16 months later in October 2018.

This additional line with a capacity of 192,000 tons per year is solely intended for the incineration of refuse derived fuel (RDF). These fuels, especially treated from commercial and industrial waste, possess a significantly higher calorific value than conventional domestic waste. Compared to the generation of energy with fossil fuels, the use of RDF to generate energy represents a cost-effective and environmentally friendly alternative. The steam generated from the plant is intended to supply the energy requirements of, for example, the companies operating in the neighbouring Oosterhorn Industrial Park. The Delfzijl location offers distinct advantages: firstly, the existing infrastructure is made use of in such ways that enables delivery of the waste by ship, rail or truck, while secondly, the supply routes for the process steam to the nearby industrial enterprises are particularly short. The industry partners will thus draw environmentally friendly energy, generated directly at the location.

The EEW-Group has been planning, building and operating waste disposal plants for over 25 years, setting Europe-wide standards in the process. As the market leader in Germany and ranked one of the top ten in the world, the company today possesses the biggest park of installations in Germany generating power from the thermal recycling of waste. With the Delfzijl contract, Steinmüller Babcock is building on the longstanding successful cooperation with EEW. This company has already put its trust in the expertise of SBENG with the EfW plant in Heringen as well as the ongoing service activities at several locations.

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Steinmüller Babcock Environment receives order for WtE plant Högbytorp

Gummersbach, 8 March 2017. Steinmüller Babcock Environment GmbH, based in Gummersbach, Germany, won the bidding process to build the boiler and furnace unit for a new waste utilisation plant in northwest Stockholm. The client is E.ON Värme Sverige AB, the Swedish subsidiary of the German E.ON Concern. The single-line waste-to-energy plant, with a performance of 100 MWth, will treat municipal and industrial waste and later supply electricity and district heating to the region. More than 80% of the annual heating needs of the E.ON district heating network will be covered by the WtE plant Högbytorp in the future. Commissioning is planned for the end of 2019.

Steinmüller Babcock Environment convinced with a technical concept that combined a tailored, sophisticated solution with a good price. This is already the second contract from E.ON Värme Sverige AB for the Gummersbach company, after the energetic optimisation of a waste-to-energy plant in Norrköping, Sweden. The contract for Steinmüller Babcock Environment encompasses the engineering, construction and delivery of the complete waste incineration unit, including the combustion grate, dry deslagging, boilers and other components of the water-steam cycle, as well as the boiler house and the façades.

The WtE plant Högbytorp is part of a location initiative for the sustainable development of the urban district of Järfälla and Upplands Bro in northwest Stockholm. It will be one of the largest thermal waste utilisation plants in Sweden. Household and commercial waste will be used. The forward moving grate installed by Steinmüller with 4 tracks and a width of more than 12 metres, is the largest that Steinmüller Babcock Environment will have delivered in its history to date. The boiler is also impressive, with a performance of 100 MWth. The combustion capacity of the plant is designed for 45 tons per hour. Furthermore, with this new plant construction, an innovative dry deslagging concept will be used for the first time in Sweden, which allows a much higher recovery of resources from slag. Thus the waste incineration plant will not only utilise the energy of the waste, but will also make a significant contribution to material recycling.

The focus of energy generation at the waste-to-energy plant Högbytorp will be on the provision of district heating. The goal is to merge the three currently existing district heating networks of the surrounding municipalities, which are currently being supplied by small older heating plants, into a large network that will be fed in an environmentally manner with energy from waste. More than 80% of the annual heating needs of the new large district heating network will be generated in future by the thermal waste utilisation plant in Högbytorp.

After its completion, the WtE plant in Högbytorp will be visible from afar as a deliberately designed landmark, even from the Swedish E18 motorway. “Typically Swedish”, the plant will receive an impressive, mostly transparent façade. The famous Stockholm architecture practice Scheiwiller Svensson Arkitektkontor AB is responsible, which also designed the project “Filmstaden Mall of Scandinavia” in Solna, among many others.

For Steinmüller Babcock Environment, the on-site operative construction phase starts in March 2018, the erection of the boiler is planned for May 2018.

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Ceremonial contract signing for new combined heat and power plant in Lithuania

Gummersbach, 29. September 2016. Last Thursday, the ceremonial contract signing for a combined heat and power plant (CHP) took place in Vilnius (Lithuania), which is expected to go into operation at the beginning of 2019. This event was attended not only by representatives of the customer, but also, in addition to the Lithuanian Prime Minister Algirdas Butkevičius, by numerous high-ranking, distinguished guests from politics, administration and business. The significance of this project was also underlined by the participation of the Permanent Representative of the Federal Republic of Germany, Michael Morgenstern.

In the procurement process, the customer, UAB Vilniaus kogeneracinė jėgainė, a subsidiary of the state controlled energy company “Lietuvos Energija”, decided in favour of the consortium led by Steinmüller Babcock Environment GmbH with the partners Budimex S.A. and Kauno dujotiekio statyba. The convincing argument of the consortium was its technical expertise and the development of a customised solution – enabling it to do justice to the high status associated with this project, which has been classified as a “project of national economic significance” by the Lithuanian Government and is funded by the European Union.

The whole project comprises the construction of a total of three lines to generate electricity and district heating: a waste incineration line with grate technology (Lot 1) as well as two biomass lines with fluidised bed technology (Lot 2). The contract of the consortium led by Steinmüller Babcock Environment for Lot 1, with an order value of some 180 million Euros, contains not only the complete waste incineration line, which also includes a connection to an existing mechanical-biological treatment plant, but also all higher-level systems for the entire plant.

Within the consortium, the delivery share to be provided by Steinmüller Babcock Environment comprises the complete process technology for the waste incineration – beginning with the waste input via the combustion system, the boiler, the flue gas cleaning and the flue gas condensation through to the chimney. Furthermore, the feedwater system, the process control system and the medium and low-voltage switchgears are also included. The Polish construction company Budimex will undertake the construction part as well as the water-steam cycle and the high-voltage connection. The Lithuanian company Kauno dujotiekio statyba will be responsible for the local planning, the district heating pipelines and the connection to the external infrastructure.

The cogeneration plant, designed for a high degree of efficiency, will help to save on fossil fuels by the thermal recycling of the waste and ensure the future supply of electricity (90 MW) and district heating (230 MW) to the population of the region.

For Steinmüller Babcock Environment this project provides yet again the opportunity to demonstrate its turnkey expertise in international plant construction. For the EfW plant in Klaipeda commissioned in the spring of 2013 – not only the first of its kind in Lithuania, but in the whole of the Baltic region – Steinmüller Babcock Environment was responsible for the planning, delivery, installation and commissioning of the complete boiler and combustion plant as well as the associated anciliary facilities, thus enabling it to substantiate its capability in no uncertain terms.

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Desulphurisation technology for India and Bangladesh

Environment flue gas desulphurisation technology and its marketing in India and Bangladesh by Indure. To ease market entry, Steinmüller Babcock Environment shall provide engineering services along with the technology, as well as support for sales and tender preparations.

“India’s new environmental guidelines stipulate the reduction of emissions in power plants, so that the maximum permitted sulphur dioxide output must now be reduced drastically. We are therefore convinced that the partnership with Indure will give us the opportunity to successfully establish our proven flue gas cleaning technologies in the growing Indian market. With Indure a partner has been found whose own engineering and production capacities have made it one of the most experienced suppliers of power plant components in the country,” explains Dr. Frank Delle, Head of Flue Gas Cleaning at Steinmüller Babcock Environment.

With many decades of experience in the area of flue gas cleaning, Steinmüller Babcock Environment is one of the leading suppliers of this technology. The Indure Private Limited is active as a general contractor in the area of planning and constructing power plant equipment, especially in India.

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Certification of grate technology for the Japanese market

Technology of Steinmüller Babcock Environment for waste incineration for the Japanese market. To this end, the joint technology transfer team proved the suitability of the technology based on Steinmüller plants that are already under successful operation, using process data, measurements and analyses, and managed to convince the experts from the Japan Metropolitan Waste Association during an inspection of the plant in Berlin-Ruhleben and also by explaining technical issues.

The Steinmüller Babcock Environment grate or waste incineration technology is therefore certified as a proven technology that is suitable for the Japanese market. This is a prerequisite and starting signal for the specific entry into the Japanese market, for which purpose Nippon Steel & Sumikin Engineering has created a new product department for grate technology.  

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Award as “Low Carbon Model Company of the Year”

Technologies to reduce CO2. This year, Steinmüller Babcock Environment GmbH was nominated in the context of the “China Low Carbon Model Peak Forum” as one of the leading companies in the field of environmental technology, and convinced the jury with its concept to reduce CO2 by using thermal waste treatment processes, anaerobic digestion, and the combination of both methods.

Numerous guests from the fields of business and politics, and representatives of environmental organisations took part in the prize ceremony, which was held in Beijing on 30 June 2015. The award has once again confirmed the corporate goal of Steinmüller Babcock Environment, “We make the world a cleaner place”, and underlines the necessity of promoting and further developing environmentally-friendly technologies.

Steinmüller Babcock Environment has already built an energy-from-waste plant in the Chinese city of Hefei, which went into operation in 2012 with a throughput of 1,000 tons per day and a thermal output of 36 MW. In summer 2013, thanks to the convincing overall achievement, Steinmüller Babcock Environment also won the contract for the second expansion stage of this plant, which once again comprises two lines, each with an output of 500 tons per day. Furthermore, the company, as co-owner of the Shanghai Pucheng Thermal Power Energy Co. Ltd., which operates a waste incineration plant in the district of Pudong, was able to gain operational experience with Chinese waste. “This know-how,” stresses the Managing Director Dr.-Ing. Gert Riemenschneider, “gives us a clear competitive advantage in the engineering of new plants, for Chinese waste contains a large proportion of organic substances. That means an extremely high moisture content and a very low thermal value. An effective firing must ensure independent incineration, despite these unfavourable waste characteristics. We have therefore developed a modified moving grate system based on proven technology, which takes account of this special situation.”

Anaerobic digestion is another solution approach for reducing CO2 emissions, as the entire methane generated during the digestion process is converted and can be fed into the public gas network. The methane is therefore harnessed, and its release into the atmosphere is prevented. This method is suitable especially in regions that do not have a district heating system, or where fast and relatively cheap solutions to reduce CO2 are sought. Steinmüller Babcock Environment also has reference plants in this area, with a capacity of 6,500 to 85,000 tons per year.

Furthermore, Steinmüller Babcock Environment invests in the research and development of new technologies that serve to protect the environment. Together with universities and partners from industry, the world’s largest test facility for CO2 emissions was developed, which can filter up to 95% of flue gas by means of so-called “carbonate looping”.

As acknowledged for some years now in Germany by the Federal Environment Agency and the Federal Ministry for the Environment, Nature Conservation and Nuclear Safety, waste incineration plants can make an essential contribution to reducing CO2 considerably. Two factors above all explain this: First, thermal waste treatment reduces the use of environmentally-hazardous landfills (in Germany the depositing of untreated municipal waste in landfills has been prohibited since June 2005). This represents a huge environmental problem, as highly hazardous methane gas, which is more than twenty times more damaging than carbon dioxide, is released from landfills in an uncontrolled manner. According to studies by the American Environmental Protection Agency (EPA), the depositing of waste in landfills is even considered to be the third-greatest cause of methane gas emissions worldwide. However, thanks to Steinmüller Babcock’s highly-developed flue gas cleaning technology, the flues gases released by a modern waste incineration plant are clean and do not represent a danger to humans or the environment.

Second, thermal waste incineration contributes to energy generation and thus spares fossil energy sources such as coal, natural gas and oil. In a study from 2005, the Federal Environment Agency stated that “the incineration of waste […] not only serves the harmless disposal of waste, but also produces a considerable amount of energy as electricity and heat. Waste incineration therefore contributes to climate protection and spares natural resources”.

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