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Reference project plant engineering

Teamwork on the plant project for AdBlue®

Dominik Dörig
Specialist Corporate Communication

Before commencing our AdBlue® production, we designed and constructed the production plant. This plant engineering project marked an inaugural collaboration between staff from our Tangstedt and Bernsdorf sites.

The team in Tangstedt also constructs its own plants.
The team in Tangstedt also constructs its own plants. For instance, the one for the site in Bernsdorf.
The team in Tangstedt also constructs its own plants.
The team in Tangstedt also constructs its own plants. For instance, the one for the site in Bernsdorf.

Team in Tangstedt

June 2023. Mike Horstmann, project manager in Tangstedt, received the order to construct an AdBlue® production plant by the beginning of 2024. It was to be installed at the newly established site in Bernsdorf. Not an easy task, as the high quality standards and the short time frame demanded an awful lot from the teams in Tangstedt and Bernsdorf.

Osmosis system and buffer silo

  • Water treatment: The osmosis system demineralises the water for the AdBlue® mixture.

  • A screw conveyor transports the urea from big bags into the buffer silo.

  • The buffer silo has a maximum capacity of 5 tonnes of urea. The screw conveyor then transports the urea on into the mixing tank.

Mixing tank and filling

  • The treated and heated water is mixed in the correct ratio with the urea inside the mixing tank. A total of 100 tonnes can be produced per day.

  • The finished AdBlue® is stored in four 30 cubic metre tanks with outgoing pipelines. That is equivalent to a volume of 120 tonnes.

  • The automatic valves at the outlet are used to fill tanker trucks, IBCs and barrels.

  • A conveyor belt in the filling system is used to fill 5 or 10 litre containers via automatic valves.

Team in Bernsdorf

The modules started to arrive in Bernsdorf in November 2023. Installation was carried out by the newly formed team in Bernsdorf, led by site manager Michael Richter and production manager Sebastian Weigel. Electrical installation was carried out by the Tangstedt plant manager Robin Schroer.

The work was completed prior to the start of commissioning in January 2024. The ISO 22241 audit was successfully conducted in February. ISO 22241 certification is a prerequisite for producers of AdBlue®. Once 2024 certification had been received from the German Association of the Automotive Industry (VDA), the licensor, in March 2024, production commenced without any delay.

Quality ensures efficiency

  • Despite a tight schedule: The plant was put into operation in March 2024. Touch panel at the control cabinet in Bernsdorf.

  • Quality is also evident when operating the plants. Clear and well-arranged displays of the osmosis system for water demineralisation.

  • The design team has ensured efficient processes. A prime example is the automatic instruments for controlling container filling.

Plant engineering skills

Throughout this project, the teams in Tangstedt and Bernsdorf showed how to successfully overcome demanding challenges in plant engineering. From analysis and planning to installation, everyone involved approached each stage with a well-defined concept and as a dedicated team.

Rapid commissioning in Bernsdorf was also down to the typical enespa modular construction method. It enables plants that are perfectly tailored to the premises and can be set up ready for production in a short period.

A success story that shows just how the team at enespa successfully completes projects.

To the AdBlue® online shop
Author

Dominik Dörig

Specialist Corporate Communication
Contact Media Relations
Armed with a degree in Organisational Communication and Journalism, Dominik Dörig gained valuable experience working at an agency. He brought his experience in marketing, public relations and event management into the SME sector. After a decade working as a communications manager and management assistant, he joined the Marcom team at enespa in Appenzell in the autumn of 2023.
d.doerig@enespa.com
+41 71 788 33 89
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