Following the start of construction at the beginning of 2016, the new pumping station building on the Emscher sewer in Oberhausen celebrated its topping-out ceremony on 4th March 2020. Daniel Schranz (Lord Mayor of Oberhausen), Ullrich Sierau (Lord Mayor of Dortmund), Uli Paetzel (Chairman of the Emschergenossenschaft Executive Board) and Emanuel Grün (Executive Board member for Water Management and Technical Services at Emschergenossenschaft) were impressed by the on-schedule construction progress and the good cooperation between the project participants. Pumping Station Oberhausen is the last major sub-project and a decisive piece of the puzzle for completion of the wastewater-free Emscher. In the future, the wastewater will cross the Ruhr area between Dortmund and Dinslaken in a new underground channel over a distance of more than 50 km. Since the slope of this Emscher sewer is greater than the natural slope of the Emscher, three new pumping stations were designed and built along the route to raise the wastewater. The other two pumping stations in Gelsenkirchen and Bottrop are already in operation. Pumping Station Oberhausen, along with the entire Emscher sewer, is expected to be commissioned at the end of next year. The Emschergenossenschaft commissioned DAHLEM with the design of the almost 50m deep excavation pit and pumping station, including the complex process engineering, control and mechanical engineering. DAHLEM is also playing a major role in the construction supervision in its capacity of a joint venture partner.
New technology for the environmentally friendly wastewater treatment is now to be installed: By the end of 2022, the Eifel-Rur Water Association is investing around 4,00 million Euros in the conversion of four secondary settling tanks at Wastewater Treatment Plant Aachen-Soers in order to effectively relieve the polluted water load. The ozonation plant has already been built and, as the largest in Europe, integrated into the existing wastewater treatment system. The wastewater treatment plant has been treating the wastewater of the city of Aachen since 1913 and is dimensioned for 458,300 population equivalents. By 2022, four secondary settling tanks will be upgraded step by step with new stainless steel central structures and height-adjustable inlet structures. The DN 700 return sludge pipes will be replaced by new stainless steel pipes. The optimization of the secondary clarification system is expected to increase the capacity by approx. 20%. A joint venture with DAHLEM as lead company has been commissioned with the project and specialist planning. The state of NRW is funding both the large-scale technical implementation and the accompanying research on the entire project of the wastewater treatment plant.
IIt is almost completed - the new construction of Mörscher Wald Waterworks, for which the ground-breaking ceremony took place in November 2018. The waterworks will be completely rebuilt according to the latest technical standards and will be put into operation on schedule, in 2021. The new building for the 70-year-old plant is constructed on a directly adjacent plot of land. Once the new plant is commissioned, the existing one will be completely dismantled and the area will be reforested. In the future, the new waterworks will ensure the vital potable water supply for the city of Karlsruhe and the surrounding communities. Investigations of the potable water demand up to 2040 showed that due to climate change and the predicted population growth, a capacity of 60.000 m³/d, respectively 3.000 m³/h, will have to be provided in the future as maximum capacity for raw water pumping and treatment. The architectural design of the building provides for a harmonious integration into the forest environment. As a partner in a joint venture, DAHLEM has been commissioned with the design of the engineering structures, the building interior space and the outdoor facilities. A BIM-oriented 3D model was created for the building design.
It is almost cojmpleted - the reconstruction of Katernberger Bach: On a length of approx. 1,1 kilometers the stream receives new space next to the old waterway. Furthermore, the stream will run openly for 1,2 kilometers. Construction started in 2019. Since the 1960s, it has been flowing through the Katernberg district of Essen mostly with pipes. The opening up of the stream and the separation of clean and polluted water as well as the renaturation of blocked waterways should improve the stream ecologically. The redesign is part of the Century Project for the ecological improvement of the Emscher system between Dortmund and Dinslaken, which started in the 1990s. By means of subsidence, the pure water produced in the upper reaches will be pumped via a new pure water pumping station to the planned disclosure section. In addition to the hydraulic engineering planning, bottom slides, fords and bridges will be constructed and several culverts will be implemented. In addition to the ecological improvement measures, experience stations will be built to make the water accessible and thus integrate it into the life of the district. The Emscher River Association (Emschergenossenschaft) commissioned DAHLEM with the project planning, structural design, technical equipment and site management for the reconstruction of the watercourse.
The wastewater infrastructure in Kosovo is in poor condition. Wastewater from settlement areas usually enters surface waters untreated. While comprehensive sewerage systems for wastewater disposal are largely in place in urban areas, the country lacks municipal and industrial wastewater treatment plants. The programme "Sewage Disposal South-West Kosovo IV" aims to improve sewage disposal and treatment in several cities, particularly with a view to sustainable protection of natural water resources and improvement of the living conditions of the population. The programme provides for extensive sewage disposal measures in the town of Peja, financed by KfW, SECO and through local funds from the town administration and the Republic of Kosovo. The total construction costs of the measures in the town of Peja amount to €17 million. They include the construction of a main collector to transport the wastewater to the treatment plant site 6 km away, another collector to connect the southern parts of the town, stormwater overflows and a fully biological treatment plant. An anaerobic-mesophilic digester stabilises the sewage sludge produced; the plant's own power supply is provided by several CHPs with sewage gas. With a planned sewage treatment capacity of 81,000 population equivalents, it is one of the first wastewater treatment plants in Kosovo. In addition to domestic wastewater treatment, the connection of an interregional brewery is planned. The municipal waste management company RWC HIDRODRINI JSC commissioned DAHLEM with the planning, functional call for tender and construction supervision of the wastewater treatment plant as well as the transport collectors.
It is a high-tech facility where everything is just about right. With outstanding architecture, a clearly defined purpose and state-of-the-art technology inside, its new digesters are, therefore, characteristic of Würzburg wastewater treatment plant. In the future, 4,500 tonnes of sewage sludge will be produced each year, with an almost tripled annual capacity of 10,000 cubic metres. This means more digester gas and more power generation. 4.2 million kWh of additional electricity can now be produced to be consumed directly on site. As a result of this measure, the CO2 balance improves enormously and the odour nuisance is also reduced. A focal point of the electrical engineering was the integration of the generated energy with the Mainfranken network in line with the Renewable Energy Sources Act. Specifically, the lightning protection system was a considerable planning challenge. Here, it was necessary to, on the one hand, adapt the components of the new digesters and, on the other, to protect their design membrane and the potentially explosive areas against lightning strikes. DAHLEM was responsible for the electrotechnical planning for all service phases.
At MARK 51º7, the former Opel factory site in Bochum, an industrial, technology and knowledge campus is currently being built that will fulfil the requirements of future work environments, supporting a work/life blend. With development at an advanced stage and the infrastructure almost entirely complete, the ambitious plan for the location is increasingly becoming a reality.For the development of the sewer and road construction, DAHLEM, as part of a joint venture, supervised the implementation of the gigantic and complex construction site. The design and construction supervision for the stormwater retention basin, with a volume of 6,500 m³ for protection in cases of heavy rain, has already been completed. The site was awarded the polis Award 2019 in its category as "Best urban surface recycling, MARK 51°7 - successful reactivation in eastern Bochum".
Even if there are no visible electrical installation works on the construction site of Pumping Station Oberhausen yet, the electrotechnical equipment ist making bis steps forward. At the factory acceptance test in Finland, two out of the 10 frequency converters of the "small" and "large" sewage pumps were successfully tested and approved by the manufacturer as the first components of the powerful drivelines. These are frequency converters with a nominal voltage of 690 V and a rated current of 1.180 A, respectively 1.700 A, which corresponds to a rated output of 900, respectively 1.250 kW. The high demand on the network repercussions with limit specifications to the harmonic, inter-harmonic and, for the first time, also to the supra-harmonic currents, required the frequency converters to install active line filters and correspondingly large-sized line reactors. These are, like the actual power electronics of the frequency converter, cooled by water. Each frequency converter consists of 5 control cabinets, with each frequency converter being approx. 3 m wide. Helmut Mangelmann heads the Electrical Engineering Department at DAHLEM and works in the team of the design consortium (Planungs-ARGE) of Pumping Station Oberhausen: "We have planned and built quite a lot in the field of electrical engineering, but these dimensions go far beyond the previous performance levels. In the low voltage sector, they are at the limits of what is technically possible in terms of circuit and transmission technology."
The government grant decision, which the Environment Minister Franz Unterseller (left) handed over to Lord Mayor Fritz Kuhn (middle) and City Director Wolfgang Schanz (right), Head of the Civil Engineering Department, on 3rd September on the spot, was the starting signal for the expansion of the main sewage treatment plant Stuttgart-Mühlhausen with a fourth treatment stage. The main sewage treatment plant Stuttgart-Mühlhausen, built in 1916 as one of the first sewage treatment plants in Germany, is operated by Stadtentwässerung Stuttgart (SES) and should count to the most modern ones in the Federal Republic by 2028. Due to the complexity and the considerable investment, the expansion will take place in three construction phases. In the first phase, powder activated carbon silos and dosing stations will be set up at the Biology North and South as well as an energy control centre will be built. The federal state of Baden-Württemberg supports this project with just under 3 million EUR. With the construction of the treatment stage for the elimination of trace substances, the City of Stuttgart is making a significant contribution to water protection in the federal state. Dipl.-Ing. Mathias Kleffmann, process expert at DAHLEM and project manager of the design consortium, is pleased. "It's great that we can now start with the direct dosing on a large-scale and implement the new process technology on a industrial scale."
By means of holistic optimization, Waste Water Treatment Plant Aachen-Soers has succeeded in reducing the enormous energy demand of the recovery by around 55 per cent. Together with DAHLEM, the Wasserverband Eifel Rur planned the modernization of the oxygen supply of the aeration tanks. The design was implemented at the beginning of the year, followed by the commissioning of the blower station mid-year. The RWTH Aachen accompanies the project scientifically. DAHLEM supported the process design, which was modeled in a 3D-planning and accompanied the award procedure. The enclosed article about the project provides detailed information about the modernization of the plant. The waste water treatment plant is also referred to as a nationwide model Enterprise.
Article, "Water & Waste Water Technology” magazine, July 2019
There was much enthusiasm at an unusual design meeting on the extension of WWTP Kleve-Salmorth, which is soon to be launched as a thermo-compact plant: plant manager Michael Offenberg and his team from the Kleve-based environmental operations were able to see how it felt in the new buildings of the waste water treatment plant. Is there enough space between the plant parts? Can one move well in between? Are there any missing components, etc. With the help of VR glasses, Torsten Wach, who is in charge of the project coordination, guided the participants through the building model, which was projected directly onto a screen. It made it possible for all involved to point out errors or changes and to rectify them before the start of construction. WWTP Kleve-Salmorth is regarded as a flagship project for innovative sewage sludge treatment and meets the requirements of the new Sewage Sludge Ordinance for Waste Water Treatment Plants to reclaim phosphorus from municipal sewage sludge in the future. Thus in the long run, the supply of this nutrient, which is central to all organism, shall be ensured. DAHLEM provides the design services, from the initial conceptual design to the award, including construction supervision.
Future-oriented flood prevention is a big topic worldwide. How it actually works is what the employees of SIGN, the Chinese-German Water Network, wanted to see for themselves on site in Germany. Dipl.-Ing. Holger Ackermann, employee at DAHLEM in Essen and member of the research project, led the Chinese delegation to various locations such as, for example, the ThyssenKrupp site, the Oberhausen pumping station and the Holtener Feld, designed and supervised by DAHLEM primarily taking into account the rainwater management aspects. As part of a subproject recommended for implementation, namely "Urban Water Management for Future Cities", DAHLEM developed a locally applicable action plan for future-oriented flood prevention in China together with SIGN, the Chinese-German Water Network.
After 26 years of operation, one of the two parallel-fed disc dryers of the sludge drying plant was replaced by a new one at Waste Water Treatment Plant Düsseldorf-Süd. In order to ensure a constant operation of the facilities, the exchange of the other rotor took place already in 2005. Before the replacement of the second rotor, a study showed that the drying of sludge by means of a new disc dryer represented the most favorable solution in terms of operating costs. With a pipe length of 8.6 metres and a heating surface of 400 m², the new disc dryer 2, partly made of stainless steel, provides a throughput of 5.2 tonnes per hour. As the previous plant part was no longer economically viable, the rotor replacement took place in March 2019. For the replacement of the disc dryer, DAHLEM provides the technical equipment planning, from establishing the basis of the project to the award, including construction supervision.