Construction of a hazardous waste treatment center, Bulgaria

In preparation for Bulgaria’s accession to the EU, Fichtner prepared for the Bulgarian Ministry of the Environment the required documents to the standards of ISPA (Instrument for Structural Policies for Pre-Accession) for an application for EU funding for construction of a national hazardous waste center. The contract covers projections of demand, conceptual planning, determination of basic data for site appraisal and selection, as well as an economic analysis to serve as a basis for the application for funding. For the project to proceed immediately upon receiving funding, in parallel outline engineering and tender documents for supply of the plant were prepared.

Extension of refuse incineration plant (AVI), Amsterdam, Netherlands

The existing plant with a waste throughput of 780,000 t/a was extended by two further incinerator trains to become the biggest thermal waste treatment plant in Europe, with a capacity of 1,300,000 t/a. An engineering joint venture under the leadership of Fichtner developed an advanced plant concept guaranteeing an unprecedented electrical generating efficiency of over 30%, without sacrificing availability and reliability. The order also included preliminary planning and system design of the developed concept, preparation for and participation in tendering with recommendations for contract award in over 20 individual lots, as well as project management, technical coordination, site supervision, commissioning and acceptances for the plant as a whole. Thanks to implementation of this project, about 200,000 t/a CO₂ emissions are avoided.

Management of a waste treatment project, United Kingdom

The company Lakeside Energy from Waste Ltd. is constructing a new thermal waste-to-energy plant near Heathrow Airport. Fichtner was entrusted with implementing and managing the EPC contract. The plant consists of two combustion trains, each with a heat recovery steam generator and the latest equipment for pollution control and flue gas cleaning. The entire plant, whose construction phase has been scheduled over 33 months, has a waste throughput capacity of 410,000 t/a and a power output rating of 37 MW. Our services cover project management, checking of drawings, site supervision, safety coordination as well as monitoring of an operation and maintenance contract over the first four years of operation. Under a separate contract and with a second, and separate, project team, Fichtner is acting as Lender’s Engineer and Technical Adviser for the project financer, the Bank of Ireland.

Hazard analysis for fermentation towers, Spain

For anaerobic treatment of wastes in five fermentation towers, each of capacity 3500 m³, and an associated biogas recovery plant at Majorca’s waste disposal park, Fichtner prepared a Hazard and Operability Study (HAZOP).

Planning services for Tuba Hazardous Waste Treatment Plant, Jordan

Under contract to the Jordanian national environmental protection agency, Fichtner first undertook a study for a facility for treatment, storage and disposal of 30,000 t hazardous waste per year. Then the resulting planning and tendering documents were drawn up. The facility includes storage tanks, physico-chemical treatment, a landfill and an incinerator.

Construction of an MSW treatment center and four waste transfer stations, Qatar

For construction of a treatment center for municipal solid waste and erection of four new waste transfer stations with the extension of an existing facility, under a public-private partnership (PPP) project, Fichtner drew up the technical proposal. The waste treatment center comprises: waste pretreatment with materials recycling, composting, thermal waste treatment, final disposal of ash, and landfill.

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Treatment and disposal of petroleum industry hazwaste, United Arab Emirates

This BeAAT (Central Environmental Protection Facilities) project was launched by Abu Dhabi National Oil Company (ADNOC) for environmentally compatible and safe treatment of hazardous wastes generated in ADNOC companies. In its role as Project Management Consultant (PMC) under contract to the Abu Dhabi Oil Refinery Company TAKREER, Fichtner has taken over implementation and management of the EPC contract. The aim is to consider health and environmentally-relevant aspects when handling ADNOC’s hazardous waste. By applying the latest, proven waste management technologies, compliance with strict health, safety and environmental protection guidelines is ensured. Consequently, the hazardous waste is to be treated as far as possible so that the remaining inertized wastes can be safely landfilled. The plant’s process chain comprises essentially thermal separation, centrifuging, compaction, incineration, chemico-physical treatment and oil-water separation followed by landfilling. Also belonging to the project scope are all associated storage and transfer facilities as well as administrative institutions. Fichtner has been involved in this project since 2001 and has already prepared the front end engineering design (FEED), conducted the tendering procedure for the EPC contract, and has aided TAKREER in selecting the contractor.

Planning and site supervision of Tuas South Refuse Incineration Plant, Singapore

For this project, Fichtner undertook complete engineering, tendering, contract award, check of drawings as well as site supervision, coordination of commissioning and trial operation, including acceptance and handover of the plant to the client, the Singapore Ministry of the Environment. It consists of six conventional stoker-fired incineration trains, each of 30 t/h throughput capacity. Steam is directed to two 66 MWe condensing turbines. The particular features of this plant are: a) it handles a high proportion of bulky waste, up to 50%, with separate bulky waste stores in the waste reception area, where it is shredded by four rotary shears, each 25 t/h capacity, before mixing in the waste pit; b) separation of facility into two independent units each with its own waste pit, bottom ash bunker, incineration trains and stack; c) application for the first time in Singapore of dioxin abatement measures by activated carbon injection, fabric filters for particulate removal, and extensive lining of furnaces with SiC tiles.

Implementation of a further refuse incineration plant as a DBOO Project, Singapore

The Singapore Ministry of the Environment commissioned Fichtner with preparation of a concept for a DBOO (Design-Build-Own-Operate) project, with the aim of preselecting private investors for international tendering. Prior to tendering, a study was undertaken and preliminary engineering prepared to define technical and commercial conditions, and review the legal framework. The plant is designed for an incineration capacity of more than 350,000 t/a, with energy and scrap metal recovery mandated. Apart from the study, Fichtner’s services cover complete engineering and tendering, design and specification of the DBOO model with formulation of contract, support of client up to project start as well as supervision of contract execution by the future operator.

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Expansion and new construction of Macau Refuse Incineration Plant, China

Macau Refuse Incineration Plant, erected in 1992, was designed with its three treatment trains for a capacity of 864 t of municipal solid waste per day (more than 250,000 t/a). Its waste energy recovery facilities generate electrical power at 12 MW. A new plant of about the same size with an incineration capacity of 3 x 288 t/d and an electrical power rating of 14 MW is to be constructed directly adjacent to the existing one. Fichtner undertook preliminary planning and then, on behalf of the Government of Macau, general planning, tendering, contract award and site supervision up to commissioning and trial operation of the extension. Additionally, Fichtner advised the client on rehabilitation of the existing plant, planned for after startup of the new incineration plant.

Thermal treatment of pretreated wastes, South Korea

At the site of the biggest landfill in South Korea, in Sudokwon near Seoul, a facility for recycling raw materials, called the Resource Circulation Management System (RCMS), is under construction. This scheme includes mechanical-biological pretreatment of municipal solid waste and a thermal treatment plant for maximum energy recovery as well as optimization of environmental impacts. Within this framework, Fichtner compared the conventional thermal technology of stoker firing with the new technologies of gasification and pyrolysis, followed by a recommendation for the most advantageous technology under the given constraints and conditions. Following basic design, Fichtner drew up the specifications for a circulating fluidized bed combustor, designed for a throughput of 400 t/day municipal solid waste (200 t/day following mechanical-biological treatment), serving as a pilot project. After successful trial operation, the total capacity of the RCMS is to be extended to 4000 t/day (approx. 1,400,000 t/a), with around 2000 t/day for thermal treatment. The steam parameters are 480°C at 45 bar.

Biowaste composting plant for Esslingen District Council, Germany

With the construction of the new two-train composting plant of 60,000 t annual capacity, one of the biggest fully automated plants in Germany was realized. Its technology is based on dynamic migrating windrow composting with full suction aeration, and it is equipped with multi-stage exhaust air treatment with scrubbers and biofilter to minimize pollutant emissions. Fichtner undertook complete engineering of the mechanical, electrical and control components, as well as the entire civil part up to structural planning. This was followed by supervision of the three supply and construction lots, as well as monitoring and support during commissioning and trial operation with subsequent warranty period. 

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Process heat supply by refuse derived fuel (RDF) combustion at Minden CHP Plant, Germany

Under contract to Siemens, Hanover, Fichtner drew up the specifications for the mechanical plant systems, buildings and infrastructure of the Minden “Energos” Combined Heat and Power Plant. This comprised full procurement engineering for these components as well as general coordination of the facility. The thermal part as well as electrical andI&C components were supplied by Energos Norway or Siemens Norway, with Fichtner also entrusted with project oversight and site supervision. This plant is operated by Energos Germany. The design throughput of refuse derived fuel is 40,000 t/a. The energy content of the flue gases is converted at 12 MWt in a heat recovery steam generator into process steam, that is then directed through a 2.5 km buried and thermally insulated pipeline for use in the chemical works of Knoll AG. The flue gas cleanup equipment produces no wastewater, and pollutant emissions are monitored continuously. The period of project execution from contract award to commissioning was twelve months.

Construction of a new sewage sludge incinerator at Stuttgart-Mühlhausen Sewage Treatment Plant, Germany

To replace a sewage sludge incineration train in Stuttgart’s main sewage treatment plant, a new fluidized bed combustor with an incineration capacity of 4 t/h TS (total solids) is being constructed. Its main components are: mechanical sludge dewatering, thermal sewage sludge drying, fluidized bed combustor, heat recovery steam generator, electrostatic precipitator I, dry scrubber, electrostatic precipitator II, flue gas scrubber, and generator driven by a 1.5 MVA backpressure turbine with heat extraction to a group heating system. The facility is designed so that, during normal operation, sewage sludge combustion proceeds autonomously without supplementary firing. Additionally, the entire plant is automated using PLC technology, and it is tied into the sewage treatment plant’s process I&C system. It is remotely monitored and operated from VDU workstations in a control room. Fichtner’s services encompass facilities engineering and supplementary specialist engineering for all services phases, starting with establishing basic data and constraints, through preliminary planning, conceptual engineering, permit engineering, detail engineering, preparation for contract award and assistance in the award process, up to project supervision. The entire construction work is being put out to tender in around 30 contract lots.

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Co-combustion of refuse derived fuels in Ensdorf Power Station, Germany

For co-firing 81,000 t/a municipal sewage sludge, 32,000 t/a meat-and-bone meal as well as 18,000 t/a wood chips in Ensdorf Power Station, Fichtner rendered engineering and procurement services. For the associated facilities – specifically transfer stations and transportation systems – Fichtner prepared permit engineering, compiled the tender documents, conducted bid evaluation and made a recommendation for contract award, finally taking over general management of project execution and site supervision.

Modernization of process I&C system with introduction of an operation management system at Berlin-Ruhleben RIP, Germany

Ruhleben Refuse Incineration Plant consists of eight incineration trains, each comprising a boiler, flue gas cleanup equipment and deNO_X reactor, together with balance of plant. The steam from the boilers is piped to Reuter Power Station for electricity generation. With its capacity of 520,000 t/a, this is Berlin’s only refuse incineration plant. For modernization of the entire process I&C installation and introduction of an operation management system, Fichtner was awarded a contract for checking and participating in the detail engineering of the contractor, ABB, as well as overseeing installation and project follow-up. This project is being executed successively in various conversion phases up to 2007. Because this incineration plant is critical for waste disposal in Berlin, top priority is given to meeting the time schedule and, in particular, fulfilling the time windows for conversions and reconnections during plant inspection and maintenance outages.

Modernization of Bremen Waste Treatment Facility, Germany

Directly following privatization, Bremen waste-to-energy plant is to be rehabilitated, to secure its economic operation over the next 20 years. For the existing control system, Fichtner prepared a concept that defined the required rehabilitation measures for planned further operation. During the planning phase, Fichtner undertook project steering for modernization of the process I&C system. For rehabilitating the service water and feedwater systems, additional services of planning, tendering, bid evaluation and preparation for contract award were rendered.

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