How it's currently going with the project sewage sludge mono incineration Halle-Lochau of S2E GmbH
sludge2energy GmbH, a subsidiary company of WTE Wassertechnik GmbH and HUBER SE, started in 2018 as builder with the construction of a sewage sludge mono-combustion plant. The location chosen is a site with good transport connections in the heart of Germany between Halle (Saale) and Leipzig.. Im Folgenden berichten wir über den laufen aktualisierten Baufortschritt zusammen mit zahlreichen Fotos und einem Zeitraffer-Video.
According to current planning, commissioning and trial operation of the belt drying and sludge incineration plant are scheduled for the end of 2021. From then on, 33,000 t of dewatered sewage sludge (dry matter content of 25%) and 2,700 t/a of externally dried sewage sludge (dry matter content of 90%) can be energetically utilised annually. The main components of the sewage sludge mono-combustion plant designed by the engineers of sludge2energy GmbH are a sewage sludge bunker including crane system, a HUBER Belt Dryer BT 20 including vapour exhaust air treatment, a S2E Fluidiser (fluidised bed furnace) with steam boiler and a dry flue gas cleaning system. The steam generated in the fluidised bed furnace is converted into electricity by a back pressure steam turbine and the low-energy exhaust steam from the HUBER Belt Dryer BT is optimally utilised.
The plant is integrated into the Recycling Management Park of Abfallwirtschaft Halle (AWH) on the site of the Schkopau landfill, which is currently in the recultivation phase. The first preparatory works for the construction of the sewage sludge mono-incineration plant Halle-Lochau started in August 2019 with the clearing of the construction site. This progressed rapidly, so that it was possible to start with the solid construction of the plant already at the beginning of November. The winter in Halle was kind to the project team, which is why the solid construction parts of the building were completed as early as March 2020.
The next step was the concreting of the floor slab, which forms the basis of the boiler house and the dryer hall. This concreting was successfully completed by the end of April 2020. Subsequently, the foundations required for the plant components could be poured and the concrete supports for the steel construction could be produced.
Until July 2020, various outdoor works were also completed. These include, for example, the ASL loading area, which enables the safe loading of ammonium sulphate. Ammonium sulphate solution (ASL) is a valuable fertiliser, which is produced during the exhaust air treatment of the sewage sludge drying process. In order to be able to load this safely into tankers, a loading area conforming to WHG (Water Resources Act) including a collecting tank was installed. The first surface layer of the plant's bypass was also constructed in order to be able to carry out the installation work in autumn and winter on clean ground.
The expansion of the plant's social building was continued over the summer. Here, the recreation and work rooms for the operating team are to be built and where the control technology for sewage sludge incineration and the turbine of the plant are to be accommodated.
The period before Christmas 2020 will be an exciting rather than a reflective time for the project. The core of the construction phase, the steel structure, will be completed before Christmas up to a height of +13.2m. After the Christmas break, the fluidised bed furnace and boiler are scheduled to be lifted to their original installation site on 11 January 2021 using a 400t mobile crane. Afterwards, the remaining large components of the flue gas cleaning plant will be lifted in and the rough assembly for both trades will take place.
Right at the beginning of the year 2021, there was a highlight on the construction site of the future mono-sludge incineration plant: On Friday 15 and Saturday 16 January, the fluidised bed furnace was lifted into the plant steel structure with a 400t crane. In the midst of light snow, the boiler, which consists of 4 individual parts, was lifted into place. On Friday, first the boiler including the 2nd train and then the 3rd boiler train were assembled. On Saturday the two parts of the economiser followed. In the news linked below you can see an impressive video of the boiler delivery and assembly.
Another milestone of the project was reached on 31 March 2021: In bright spring sunshine and in the presence of the two managing directors of sludge2energy GmbH Harald Plank and Manfred Graf, the HUBER board member Rainer Köhler, and the project team, the boiler pressure test was successfully passed. The fluidised bed furnace, which was installed in January, was pressurised with 107 bar water pressure in the steam boiler and steam drum. After the pressure was kept constant for half an hour without any problems, TÜV Austria gave the green light.
The commissioning of the sewage sludge monocombustion with trial operation and performance tests will take place in the 4th quarter of 2021. The start of regular operation and handover to the operators is scheduled for March 2022. The team of sludge2energy GmbH will keep you informed about the further progress of the project.