• From gas-fired heaters to biomass

    With the Net Zero project, our partner – the EGGER Group – is clearly committed to the climate-friendly industrial production of products and is thus contributing to a future worth living. We are helping.

EGGER Group – Unterradlberg site

Tradition and state of the art

Although the Unterradlberg site near Vienna in Austria is the 3rd oldest site of the EGGER Group, it is state of the art in the wood-based materials industry thanks to continuous modernisation and investment. Around 500 employees work at the site. In addition to artificial intelligence, the EGGER Group’s competence centre at the Unterradlberg site also deals with the topic of sustainability, in particular CO2 savings.

In the implementation of its projects, EGGER is clearly committed to its own ‘Net Zero’ mission, which we at NESS Wärmetechnik are very happy to support.

Our joint project ‘Thermal oil heating with biomass’ saves the site a further 10,000 tonnes of fossil CO2 per year and thus continues to help achieve the company’s goals in this area and set industry standards.

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Biomass instead of gas firing

Sustainability is a huge issue

One of the biggest projects is the joint project with us. The previous supply of process heat exclusively from two gas-fired heaters has been expanded to include a steam-thermal oil heat exchanger, which means that the supply is primarily provided by steam from the biomass power plant.

As a result, the EGGER Unterradlberg site now produces the hot thermal oil with biomass and only needs a small amount of gas compared to before. With our expertise in this area and a strong partnership, we are supporting the EGGER Group in its ‘Net Zero’ mission.

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1) Determine heat demand

Determining the heat requirement for the current status and growth forecast

Together with the customer, we determined the process heat requirement (thermal oil) for the supply changeover. In addition to the possible power plant output of the biomass plants, forecasts for the further expansion of the plant were also determined and included in the planning. This also ensures that additional consumers can be retrofitted at a later date alongside the existing continuous chipboard press.

  • Boiler house

    View of boiler house before modernisation. Depiction of cramped conditions.

2) Technical solution

Technical solution with high savings potential

As the site already operates a biomass plant for high-pressure steam generation, the decision was made in favour of a steam-thermal oil heat exchanger.

This replaces process heat from the gas-fired heaters that heat the ContiRoll with thermal oil.

This solution, which at first glance appears technically challenging, leads to high savings in fossil energy and was successfully implemented by our engineering team.

  • New stage

    New stage for heat exchanger in boiler house

  • Heat exchanger

    View of the top side.

  • High-pressure condensate pump

  • Extension system

    New tower for the grounding system.

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3) Construction

Constructive implementation

One of NESS Wärmetechnik’s strengths lies in its experience with extensions and modernisations. The existing boiler house was therefore measured with a 3D scan to determine the required system components based on the current infrastructure. This enabled the space requirements to be optimised and the existing infrastructure to be taken into account.

In a previous engineering assignment, the feasibility of the project was confirmed with the customer and an investment budget was determined.

  • 3D design

    After measuring the existing boiler house with a 3D scan

4) Realisation

Fast and unerring realisation

From an economic point of view alone, it was now necessary to realise the entire conversion while the plant was in operation. Planned shutdowns were utilised to integrate process-relevant interfaces.

Even during commissioning, the downtimes were reduced to hours thanks to good planning and the customer was able to continue production almost without a hitch.

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