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energy chain and cable for continuous operation in waste bunkers

Austrians produce around 3.5 million tonnes of waste every year. Nowadays, waste is usually disposed of in thermal recycling plants, where the ovens reach temperatures of 1200 degrees Celsius in order to utilise the waste as completely as possible. A sensitive system in which plant failures would have enormous financial consequences. A scenario that Richard Krassnitzer, responsible for the maintenance of the cranes at the Simmering hazardous waste recycling plant, does not even want to conjure up in his mind. He therefore tries to play it as safe as possible to avoid breakdowns. Today, roller energy chains from igus® are therefore used in the plant.

Profile

  • What was needed: readychain® energy supply system incl. all necessary special parts, plates and machine parts
  • Requirements: heavy utilisation of the solution in continuous operation, heavy dust load in the waste bunker
  • Industry: Composting and waste incineration plants
  • Success for the customer: Reliable chain system that can also withstand the aggressive environmental conditions, provision of the ready-to-install system on the specified installation date
Industrial plant with large pipes and a steel structure.

Problem

As part of the maintenance of the cranes in the Simmering hazardous waste recycling plant, the operators were faced with the task of procuring a new energy supply solution. Initially, this task was performed by trailing cables, which - after an initial maintenance-free period - started to break down after around six months. In some cases, the cable jumped out of the guide or broke immediately. With this sensitive system, system failures would have enormous financial consequences, so the process in a waste incineration plant does not envisage any downtime for the waste bunker crane. It has to function smoothly, 24 hours a day, 365 days a year. The bunker has a capacity of 40,000 cubic metres. The system is fully utilised and the cranes in the waste bunkers run in continuous operation. Their task is not only to receive the waste and stack it in the bunker, but also to feed the ovens. The operators are therefore reliant on the cranes working continuously, if possible without maintenance.
Another challenge for the new solution is the high level of dust in the waste bunker, which means that protective clothing must be worn on site. The technology, on the other hand, has to look after itself. The damp dirt present, together with the metal particles it contains, is PUR poison for any energy supply solution.

Solution

The Lower Austrians now rely on a rolling energy chain solution from igus®. The two cranes at KW Kranwerke AG, which are equipped with the fully assembled readychain® energy chain systems from igus®, now run smoothly in the truest sense of the word.
In the energy chain, the cables are always guided in a controlled manner, which is very important for data cables in particular. The bend radius is predetermined by the chain. This prevents the shield from opening in shielded cables. However, users are also receptive to the energy chain's modest space requirements: if the crane run exceeds certain lengths, trailing cables may require more space for the cable station than the local conditions actually allow. This problem does not arise with the chain. Even with a track length of 200 metres, there is always room behind the trolley drive.
From the procurement of all necessary special parts, sheet metal or machine parts to the provision of the ready-to-install system on the specified assembly date, the customer has transferred its procurement logistics to igus®. With the comprehensive product range, igus® was able to reliably fulfil all customer requirements.

"The igus®-energy chain has never let me down. Three years after commissioning, the umbilical cord of the waste bunker crane still looks as good as new. Apart from the thick layer of dust, of course."

Richard Krassnitzer, responsible for crane maintenance at Fernwärme Wien

Conveyor belt with cable carrier in an industrial facility.
Cable carrier guides cables over a machine edge.

Before and after: the operator is delighted with the difference.

"With the trailing cables, we were always struggling with failures. There were a lot of commands running over copper wires, and the interfaces were particularly vulnerable. We often had to tighten something somewhere and make sure that the individual terminals or wires were tight again. We always had 1000 metres of different cables in stock to mend any breaks. During the repair work itself, we had to take regular breaks to feed the oven in between," Krassnitzer recalls the time before he became acquainted with the igus® system. Initial scepticism quickly turned into enthusiasm for the Cologne energy chain system: "The igus® energy chains have never let me down. Three years after commissioning, the umbilical cord of the waste bunker crane still looks as good as new. Apart from the thick layer of dust, of course." And for the Simmeringer's reserve chain, it's still 'please wait' - no emergency that has occurred so far. If the forecasts of igus® product manager Theo Diehl are anything to go by, this will not happen for years to come. This is because wear and tear is not an issue with cable carrier systems from igus®. A fact that Bernhard Bogner from AVN also appreciates. Although he has a maintenance dome for the waste bunker cranes, there is only one possible time per year for the longitudinal chain inspection: "Our main inspection." Then there is a short break in waste delivery and incineration at MVA Dürnrohr.

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