ZAB ready for the future

The "Optimization Energy Park Bazenheid" project includes the complete replacement of the more than 35-year-old kiln line 3, the replacement of all dedusting lines, and the complete renewal of the current wet-chemical cleaning into a dry cleaning stage for all three kiln lines.

With an investment of around 63 million Swiss francs, the Zweckverband Abfallverwertung Bazenheid (ZAB) has made itself fit for the future. With this expansion, the basis for a regionally comprehensive district heating network and a reduction in own energy consumption of 20 to 30% was realized.

Rey Technology was contracted for the planning and implementation of the entire process automation, including the manufacture and installation of the switchgear.

The fact that the implementation had to be carried out in 7 phases, during ongoing operations, was taken into account in the execution planning and implemented in an exemplary manner.

In a first phase, the preparatory work for the conversion was started, and at the same time the complete kiln line 3 was dismantled. This was followed by a central intervention in the entire Siemens PCS7 process control system. The complete process control hardware was transferred to a virtualized system environment. During the virtualization, special attention was paid to the newly required screen formats. The adaptation of all system screens to the new screen resolution was mandatory. In the same period the Siemens SIMATIC software project, of the more than 13 Siemens AS400 controllers was upgraded to the current PCS7 version. The firmware versions of the Siemens AS controllers were also checked and brought up to date. This created the basis for integrating the new plant components, such as firing line 3, flue gas dedusting line 3, and dry discharge, into the virtualized environment.

A time window of 32 h was provided for the integration of the virtualized system at ZAB. All the necessary control cabinet conversions also had to be completed within this time. The entire system could be returned to operation before the end of this time window.

To ensure the operation of the plant at all times and the tight schedule were a particular challenge. Careful and very detailed project planning were necessary to successfully implement this project.

The tight delivery situation of the suppliers also had to be taken into account accordingly. Finally, together with ZAB, the commissioning could be started and implemented according to the given schedule.

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