Customer Description

AVG Abfall-Verwertungs-Gesellschaft mbH is part of the Indaver Group, which operates throughout Europe, and runs one of the most modern waste management centers in the world at its Hamburg site. The company focuses on the safe, sustainable, and environmentally sound treatment of hazardous and non-hazardous waste from industry and the public sector.

The central component is the high-temperature incineration plant, with a capacity of 100,000 metric tons per year. The waste heat generated during the incineration of hazardous waste is fed into Hamburg’s district heating network via an adjacent combined heat and power plant—a significant contribution to energy recovery and CO₂ reduction.

Project: Upgrade of the feeding system for rotary kilns

After approximately 30 years of operation, the existing system for feeding large containers was completely dismantled and replaced with a state-of-the-art, flexible conveyor solution. The goal was to adapt the feeding of the rotary kilns to meet current requirements for process reliability, flexibility, and automation.

The new system allows for the differentiated storage and feeding of various types of containers—such as drums, canisters, hobbocks, or buckets—according to their load class. Automatic control is based on a combustion schedule and continuous emissions monitoring.

Technical Highlights & Safety Concept

Conveyor and Control Technology

• Batch Handling: Batch-by-Batch Loading Based on Container Classification
• Container types: drums, canisters, buckets, etc., up to 300 kg
• Max. dimensions per container: 700 × 700 × 1,000 mm
• Capacity: Up to 16 containers per hour per oven
• Buffer storage: >60 containers – enables 2 hours of self-sufficient operation
• Weighing cells: Accurately measure the amount of waste fed into each furnace
• Telescopic conveyors: Minimize transfer gaps; transfer to rakes and furnace lifters

Ergonomics & Safety

• Container Lifter: Ergonomic lifting height for manual operation
• Rotary tables (telescoping): Can be used on both sides for flexible configuration
• STAHL Control Consoles: ATEX-certified for manual and on-site operation
• Security Plan:
  • Explosion-proof design in accordance with the ATEX Directive
  • Gas Detection System for Ambient Monitoring
  • Modified security fence system with photoelectric sensors and access doors equipped with safety contacts

Process Integration

• Control via redundant Profibus and Beckhoff I/O modules
• Integration with the ABB process control system
• KKS Labeling for Complete Technical Documentation
• Reintegration of Existing Plant Components to Conserve Resources

Conclusion

This project demonstrates how SCHÖNAU combines technical complexity, safety requirements, and sustainability goals. AVG Hamburg’s new feeding technology is robust, flexible, and fully integrated—ready for decades to come of safe hazardous waste recycling at the highest level.