January this year, the new FGD Gypsum silo at the Nikola Tesla power plant in Beograd, Serbia went into operation. After finishing the building process and the installation of the material handling systems last year, the cold commissioning took place in autumn. With the first production of the new desulphurization plant we could successfully execute the hot commissioning this year. 

Environmentally safe solution

The FGD Gypsum silo at the Nikola Tesla power plant is one of several flue gas desulphurization plants built by Mitsubishi Heavy Industries in a number of Balkan countries. In order to reduce the negative effects of sulfur dioxide (acid rain), older power plants need to be equipped with flue gas desulfurization plants to remove sulfur dioxides from the exhaust of thermal power plants. This is achieved by driving the exhaust through a milk of limestone, which causes the sulfur dioxide to stick to the limestone. This limestone than transforms into Flue Gas Desulfurization (FGD) Gypsum. This wet FGD gypsum slurry is input for the Eurosilo which is dewatered and stored before shipment to producers of gypsum products, working towards a better environment.

Ensuring reliable operation

With a fully automated material handling system for a sticky bulk material such as FGD Gypsum, all components and the complete integration are thoroughly checked during commissioning. Jan-Willem Hanskamp, manager Project Department ESI: “Using scripts and checklists, we run tests on the software as well as electro technical and mechanical components. It all has to operate as one dependable system, which accurately switches from one step to another in each process flow. For the infeed as well as the output of the gypsum, there are different programs to ensure an infeed capacity of 150 tons per hour and an outfeed of 40 to 50 tons per hour. On request we also provided an air extraction system for dust free truck loading, including a filter to prevent dust emission in the surrounding.”

All-in-one storage system

The FGD Gypsum silo at the Nikola Tesla power plant combines dewatering, 10.000 m3 storage capacity and reliable discharge. By combining these three basic functions in a fully automated logistic flow, we can achieve the smallest possible footprint with just one facility. This is one of the main benefits at existing plant sites that offer limited space for new installations. As a result, this new FGD Gypsum silo is one of no less than 72 units that we have built around the world.

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After careful consideration Lyckeby, one of  Swedens leading potato starch producers, decided to work with the Eurosilo system for their most advanced new potato starch silo. We’re excited to be part of the project that will result in a 50.000 ton storage silo. As their largest potato starch silo, next to three existing silos at the production site in Nöbbelöv, it will stand out as a landmark in the country side. 

Dependable automation

To support the strategic plan for expansion and increased production at Kristianstad, Lyckeby investigated the renowned Eurosilo system for automated handling of potato starch. ESI facilitated visits to the closest reference sites at KMC, the largest potato starch producer of Denmark with multiple Eurosilos in operation. The fruitful exchange of information between technical experts and project leaders, as well as the support from the ESI team, led to the assignment October last year to design and supply the custom built silo mechanism. The civil construction will be done by Thage i Skåne AB, a leading building constructor.

Sustainable growth

As stated by Lyckeby, it is the first silo of this size to be built in green concrete, a climate-improved concrete, which means a significantly lower climate impact and approximately 120.000 kilo of reduced carbon dioxide emissions. As an agricultural producer Lyckeby is driven to be a part of a sustainable future and therefore takes great pride in integrating the next generation potato starch silo into their production site.

Design and delivery

The design and delivery of all components will take place during 2024, while the commissioning is scheduled for May 2025. Senior Project Leader Jan-Erik Dijksman at ESI oversees the project phases: “We finished the engineering in February, so we could start with the production phase of all mechanical components in March. The first shipments of components that need to be integrated into the foundation of the silo already took place. After factory acceptance tests of the silo mechanism, it will take about 10 trucks and two special transports for the large frames to ship everything to the building site. This is planned for October, after which an ESI supervisor will direct the assembly with the local crew.”

Onto the next milestone

From our experience in projects around the world, we know that working together and taking ownership are vital to make multidisciplinary projects with different partners work. We are looking forward to achieving the next milestones, including the majestic ‘big lift’ when a 500 ton crane will hoist the silo mechanism over the 43 meter high silo wall into the silo.

More information

For more information have a look at Agribulk | Strategic advantage in food supply chain | ESI Eurosilo or download the case study here Case Study – Agribulk industry KMC (eurosilo.com)

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With a growing demand for aluminum, steel and cement, the need for petcoke as a fuel for the producing industries is predicted to grow consistently in the coming years. This drives the need for storage facilities that meet the highest standards in safety as well as environmental responsibility and operational performance. How to expand at already crammed refineries, ports and production plants? By using vertical storage. Saving space was decisive for EPC Contractor KT to choose the Eurosilo system for the new coker unit at the INA refinery in Rijeka, Croatia.

Saving valuable space

By choosing to work with the compact vertical storage of the Eurosilo, KT was able to position the storage facility on premises near the new coker unit that they are building at the Rijeka refinery in Croatia. This saves them and end-user INA the huge costs of land reclamation at the seaside, where the production site is located. Compared to conventional storage in storage halls, the Eurosilo system reduces the required space to just 25% for the same amount of petcoke. Petcoke is derived from crude oil by means of a cracking process that takes place in the coker unit.

Very high standards

As always the safety standards in the petrochemical industry are extremely high. But, same as with the Hunutlu Power plant, the location at the sea added a long list with specific requirements to that, to meet environmental issues. Due to the fully enclosed storage of petcoke within the silo no dust emission sources to the environment are present. Within the silo the flow of petcoke is contained within a telescopic loading chute. While stored, the condition of the petcoke is continuously monitored by gas detection sensors to ensure that potential risks are detected in an early stage. The system meets the standards by NFPA/ATEX regulations. In order to guarantee flawless output at the required rate, the petcoke silo comes with a redundant hopper system. The flow is controlled by vibrating discharge units to enable a consistent and reliable flow to the ship loading system. Ships can be loaded at maximum rate without any delays.

Building phase of the silo

ESI received the order to provide the state-of-the-art petcoke silo in 2021. All mechanical and electronical parts have been designed, produced, tested and delivered at the site. Currently the concrete civil structure is being constructed, which means the silo walls are slip formed onto the solid foundation at the construction site. Richard Spaargaren, ESI sales director explains: “Of course we are drawing on our experience with the awarded twin petcoke silos for Orpic in Oman. But the decisive factor – saving valuable space at plant sites – applies to many more producers that need to step up to the growing demand for petcoke in the coming years.”

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Webinar Highly Efficient Fertilizer Storage at Ports

Save the date: 25 January, 15:00 CET and join the webinar about future-proof fertilizer storage at Ports. In this 4th episode of dry bulk expert talks Lukas Paul, Head of Ports & Terminals BEUMER Group, and Richard Spaargaren, Sales Director ESI Eurosilo will discuss the challenges and opportunities for this essential commodity that needs special attention at today’s modern ports. 

Join us at your own place

While it is common knowledge that fertilizer needs enclosed storage to protect it from environmental conditions, the Eurosilo system incorporates special technologies that help to minimize the footprint of fertilizer storage and maximize the automation. Starting from such a specific solution and discussing the pros and cons of the Eurosilo – and other solutions – we aim at creating a comprehensive landscape of options when thinking about fertilizer storage. You can simply join the webinar from your PC, Mac, iPad or smartphone, so you don’t have to miss out on this opportunity.

Register here to receive the link to the webinar: Meeting Registration – Zoom

Protective storage and uncomplicated reclaiming

For hygroscopic materials such as fertilizer it is essential that humidity is kept at a minimum. The concept of enclosed vertical storage offers a controlled environment inside and a well-protected environment outside. Using the slotted column system to ensure uncomplicated reclaiming increases the storage period and provides more logistic control in the supply chain. This open channel in the stored mass ensures that the product freely descents to the bottom side of the silo. The Eurosilo system is a proven solution for a wide range of fertilizers like Ammonium Sulfate, Potash and Common Salt.

See you at PortZone

Thinking about more efficient fertilizer storage at ports or plants? We will elaborate on the latest use cases of the Eurosilo, discuss learnings, challenges and pitfalls and also look at different options. See you on January 25, 15:00 hour CET (13:00 UTC) at PortZone!

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About the MBO

The management buy-out will not bring major changes to the organization. The new owners themselves have been jointly responsible for defining and daily implementation of the strategy of ESI Eurosilo in recent years. Henri de Boer: “ESI Eurosilo has been a reliable partner for stakeholders in recent years with proven growth potential and future prospects, for both quantity and quality. In the coming years we want to continue this. Not with the intention for significant growth, but to have sufficient capacity to fulfil the international, interesting and technically advanced assignments and to (continue to) do so in the different market areas.”

Jaap Ruijgrok is convinced that the chosen path is the road to further success: “I look back with pleasure and pride in the things we have achieved. The MBO is an excellent way to secure the succession as well as the future of ESI Eurosilo as an independent and flexible company with direct lines. It will be a pleasure to stay involved in near future as the Business Development Manager for the company.”

About ESI Eurosilo BV

ESI Eurosilo develops, produces and builds storage systems since 1971. The new owners are enthusiastic about their business: Henri de Boer: “ESI Eurosilo is a solution provider of storage facilities for non-free-flowing bulk materials and storage mammoth dimensions. Our fully automated silos offer maximum control in bulk solids handling (up to a size of 100,000 m³), savings on OPEX and CAPEX, and meet all environmental and safety requirements.”

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