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Eggersmann Anlagenbau completes waste recycling and RDF plant in Dubai

Eggersmann Anlagenbau GmbH, part of Germany-headed construction, recycling and biogas technology provider Eggersmann Group has completed he engineering, planning, and construction of a recycling plant for industrial, commercial and household waste in Dubai, United Arab Emirates (UAE). The official opening ceremony of the Farz plant took place on February 3, 2020, officiated by the Minister for Climate Change and Environment of the UAE, Dr Thani bin Ahmed Al Zey.

View of the new  Farz 1 200 tonnes-per-day recycling plant in Dubai, United Arab Emirates (UAE) shortly before the official opening ceremony that was held on February 3, 2020 (photo courtesy Eggersmann).

The original contract for future cooperation between the clients Ramky Enviro Engineers Middle East and Eggersmann Anlagenbau was signed in December 2017. In addition to engineering design and planning, the scope of the order also included the procurement, manufacture, and delivery of the entire plant technology and components as well as assembly and commissioning.

The official acceptance and handover took place to the agreed schedule in December 2019. The plant is operated by Farz, a joint venture between Ramky and Imdaad.

The waste recycling plant in Dubai was designed to manage the day-to-day industrial and commercial waste from the world’s largest offshore industrial park, Jafza Jebel Ali Free Zone. In addition, the majority of the waste from the WORLD EXPO, which will take place in Dubai from October 2021, is to be treated in the Farz recycling plant.

Three-stage process

A throughput of around 700 tonnes of commercial waste and 500 tonnes of household waste per day, is processed at Farz in three stages. In the material receiving area of the 2-line plant, the material composition is assessed to determine whether the material must be pre-sorted as a first step or whether it can be forwarded directly for processing in the plant.

With commercial waste, pre-shredding is needed due to the large volume of bulky solids. Two Eggersmann TEUTON stationary shredders are in use around the clock and process a total of around 1 200 tonnes per day before passing on the material to the trommel screens that are also supplied by Eggersmann.

Two Eggersmann stationary TEUTON shredders are in use around the clock and process a total of around 1 200 tonnes of waste per day (photo courtesy Eggersmann).

The screening operation is followed by separation of ferrous and non-ferrous fractions as well as the sorting of plastics, cardboard, and paper with near-infrared (NIR) devices. Eggersmann ballistic separators then split the plastic fractions into flat and three-dimensional parts.

Other infrared devices sort the three-dimensional plastics into polyethylene terephthalate (PET) and high-density polyethylene (HDPE). The recycled fractions of PET, HDPE, paper, cardboard, ferrous, and non-ferrous are then pressed into bales and returned to the material cycle.

The residue fine waste fractions are pressed into containers for subsequent disposal to landfill. The remaining high calorific value fraction is supplied to a cement works for use as an alternative fuel (RDF).

Option to expand

The waste recycling process allows for the recovery of about 25 – 30 percent of the volume, which correspondingly relieves the current landfill. The emissions of carbon dioxide (CO2) and methane (CH4) also lowered considerably. At the same time, RDF is obtained, thus reducing the use of fossil fuels in the cement plants.

The implementation of this system is particularly important to us. As part of the material receiving area and recycling plant hall, a control room with 5m high glass panoramic viewing panes and a visitor room have been created, in order to receive, train and make visitor groups aware of the issue of recycling. In order to allow for future options, there is an area for expansion on the plant site for a second plant of the same size, commented M. Goutham Reddy Managing Director Ramky Group.

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