Special solutions in DDC’s environmental investment

The works of the Vác Plant’s new environmental project are currently on the way. The project began in 2016 in order to further minimize dust emission, and as a result the plant will possess the most advanced manufacturing technology. We asked Zsolt Szilágyi, Head of Production, about the currently ongoing works. 

 

What has happened until now within the project? What tasks have been realized?

The first part of the project was finished in early March, 2017. The phase included the replacement of two cyclone heat exchangers and the flue gas conduit as well, in addition to the partial modernization of the clinker cooler. In April the foundation works of the new calciner tower were finished, while at the same time the bypass and the 32 meter-high silo were also built.

When will the next cycle start and what will be its most important part?

Building a Bypass silo during the modernisation.

The next cycle will begin in the end of July in cooperation with IKN GmbH. The construction works of the steel structure of the new calcinatory will start, while electrical engineering works will also be carried out continuously. These will have to be finished by early October.

What was the biggest challenge yet the project had to face?

A project in such a scale is a challenge for every participant, since the smallest error can lead to the complete disruption of the work, not to mention further additional costs. The biggest challenge was coordinating the works carried out by employees in different areas so that it allowed us to get closer and closer our goals.

Did you use any special technology during the modernization?

During pile foundation we made 15 meter long piles with diameters of 1200 mm, in which we then placed rebar and concrete mixed from a recipe especially created for this one task. For the construction of the silo we used a special sliding damper construction technology, with 24 hours of work.

Did you have to react to anything unprepared during the works?

I would mention the extreme cold weather we faced in January, which really strained the already tight deadline. We had to reorganize in order to secure the quality of the work and of course to protect the health of our workers.

(The interview was given in June, 2017)