AVR is an expert in processing various types of household and residual waste. AVR’s mission: to ensure that waste is not discarded, but rather given a second life. A second life in the form of energy and raw materials. To make this happen, the waste treatment process has to run like clockwork. Without a single interruption. To ensure continuity, AVR asked us to replace the conveyor system controls across the board.
Energy generation & heat production at AVR
AVR specialises in converting household and residual waste into energy and raw materials. AVR then uses that energy to generate enough electricity to meet the annual requirement of about 200,000 average households. To give you a concrete idea: that’s almost all of The Hague! In addition, AVR delivers enough heat to the heat network to keep 160,000 average households warm. That is roughly equivalent to the number of households in the town of Utrecht. And, as if that were not enough, AVR also supplies high-pressure process steam to industrial customers in the Port of Rotterdam.
Continuity = key
To keep this story understandable for you, we first need to briefly explain what we mean by the term ‘slag’. You will come across this term in this case study. Read on for an explanation in this context. When waste processors refer to slag, they mean the residue left over after the waste has been incinerated.
AVR contacted DWG and asked us to replace the control arrangement for the slag conveyors. Once all this equipment has been updated, AVR will be able to rely on a continuous production process again. This because the slag conveyors are an essential part of the waste treatment process. If the slag conveyors are not running, the incineration slag cannot be removed. And if the incineration slag cannot be removed, energy generation and heat production cannot take place. To cut a long story short, AVR needs reliable slag conveyors that are perfectly controlled.
How did we approach this?
Both our software engineers and hardware engineers contributed their expertise to this project. They were involved in the project from start to finish: from defining the specifications to final delivery and testing of the control system.
We analysed the current process for the customer. Then we answered questions like: ‘What can be done better?’ And, ‘Where can we improve efficiency?’ We also looked at how to avoid process interruptions as much as possible, to give AVR maximum continuity.
Then our software and hardware engineers looked at what engineering solutions were needed to optimise the control system. This requires seamless collaboration between the two departments. After all, effectively setting up a new control system like this hinges on proper integration of all the components and links.
AVR knew that the result would be a coherent and complete whole because DWG handled the entire project from A to Z. The customer also experienced having a single point of contact as a positive benefit. As a result, additional requirements or changes to the project were tackled and implemented without major delays.
Execute, manage and coordinate
The end result was an efficient parallel control system, which allowed smooth and event-free migration of the slag conveyors. Without any lengthy interruptions or loss of functionality in the existing system. The new system has been set up redundantly and comes with product support for the next ten years (Siemens PCS7). Thanks in no small measure to meticulous internal and external collaboration, we were able to complete the project safely, even under difficult circumstances due to the coronavirus pandemic.
“The collaboration between the team at DWG and the team at AVR was highly successful! Especially when you consider that this project was unusually complex. DWG’s engineers demonstrated their ability to successfully convert an installation without having to shut down production. The end result is that AVR now has a highly reliable conveyor system for removing slag!”
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