The best customized modification
Bietigheim-Bissingen, July 2016 – Not all modifications are equal. This motto also applies to exhaust-air purification systems. The experts of Dürr's Clean Technology Systems division have extensive experience and have successfully completed a number of complex modernization projects in a short space of time. They know that there is not just one solution which can be applied to all exhaust-air purification systems. At Dürr, detailed pre-engineering is the key for ensuring the most economical modification, explains Patrick Dippon from the sales team.
What are the reasons for modifying existing facilities?
Patrick Dippon: The main reason is a change in production, for example when new products are added or the level of production has significantly dropped or increased. What surprises me is how often plants are modified because they were built far too big due to incorrect assumptions. In these overdesigns, the exhaust air to be cleaned is made up of other substances, or the exhaust-air volume is significantly lower than anticipated. The third typical case is a plant that is showing signs of age and is no longer state-of-the-art.
What benefits do modifications offer customers?
In a nutshell, I would say that customers save resources and end up with an exhaust-air purification system that is perfectly adapted to their current or future production method. The risk of downtime is minimized. The operators have one state-of-the-art plant for which all spare parts are available.
What is the standard procedure for these projects at Dürr?
We usually follow a set procedure, although we do work out the most economical solution for the operator on a case-by-case basis. At an on-site meeting we analyze the present condition of the exhaust-air purification plant. This means we establish how the plant is run currently and not how it was planned. This is followed by an intensive pre-engineering stage, which consists of an accurate 'as is' survey and detailed concept development. We then present our results to the customer. Together we discuss our proposed modification and the associated costs. And we clarify, for example, whether the project will be implemented in one go or step by step.
We must bear in mind that there is not a one-size-fits-all solution. We deal with different types of plants and different ages; the customers' objectives can vary a lot, which also depends on their specific national conditions such as legislation and energy prices. Our customers benefit from the experience of our employees in all major market regions around the world. We can also develop suitable modifications for complex cases.
Modifications must be completed within a short time frame. Thanks to their skills and experience, Dürr employees can minimize delays in project execution.
What particular challenges do you face when carrying out projects?
Short downtimes are the main challenge. We usually have around two weeks to complete projects. Downtimes are planned way in advance and cannot be moved – one of my customers had planned this period seven years in advance. What this means for us is that we cannot afford any major delays in our preparatory work. Another important point is that a modification project is always an intervention in a functioning system. Process and control are closely coordinated and must now be carefully adjusted. Our intensive pre-engineering enables us to minimize the risk of delays.