Background

Max Aicher GmbH & Co.KG operates in the business areas of Steel & Production, Environment & Recycling, Real Estate & Projects, and Construction & Engineering.

MAX AICHER plans to set up a production facility for graphite electrodes (for electric arc furnaces). A technical center with a graphite green production facility is to be built at the LSW Lech-Stahlwerke GmbH site in Meitingen and later expanded in a modular fashion. 

MAX AICHER commissioned Projektingenieure (PI) with the design and implementation of the new technical center.

Results

• New production hall (technical centre) for the green production of graphite electrodes, including laboratory, offices and social rooms.
• Dismantling of old facilities in Grießheim and reconstruction of the refurbished facilities in Meitingen.
• Production subdivided according to process steps and ATEX areas.
• New filter system.
• Implementation of the highest requirements for occupational safety, environmental protection and energy efficiency.

PI services

Factory planning, process planning

Concept design
analogous to VDI 5200, phases 2 to 3

• Capacity requirements and material flows simulated
• Production areas defined according to process steps and ATEX requirements
  • Mixing
  • Heating
  • Crushing
  • Mould filling, pressing, demoulding
  • Cooling
  • Sending for graphitisation
• Logistics concept (material flow, staging areas, conveyor systems) created
• Layout start and modular extensions created
• Resources (personnel, equipment, buildings, infrastructure) dimensioned
• Investments determined
• Master plan for implementation created

Detailing 
analogous to VDI 5200, phases 4 and 5

• Detailed manufacturing segments
  • Machine layout plan created
  • Diagram for process flows and media supply created
  • Piping and instrumentation diagram (P&ID) created
  • Equipment list created
  • Plant technology (including filter technology) specified
• Relocation and overhaul of existing facilities specified, put out to tender and prepared for awarding contracts.
• Plant engineering put out to tender, bids obtained and prepared for awarding contracts.
• Buildings and technical systems (hall ventilation, exhaust air purification, etc.) specified.
• Approval documents prepared.
• Budget and schedule drawn up, project controlling established.

Implementation
analogous to VDI 5200, phases 6 and 7

• Managed supplier performance, organized acceptance procedures
  • Installation/integration of newly procured equipment
  • Relocation/integration of existing systems
• Budget (investments) tracked

Topics

Factory planning: Value stream, production segments, material flow, layout, scalability, step-by-step expansion, facilities/infrastructure/buildings, cleanliness, environmental protection

Process planning: Process engineering, plant engineering, simulation of capacity requirements, automation, interlinking, energy efficiency, IT, control technology, machine and process data acquisition, Industry 4.0

Logistics planning: Conveyor technology: Warehouse technology/transport technology, order picking technology, fire protection

Trades

Gating, mixing, heating, crushing, mold filling, pressing, demolding, cooling, shipping for graphitization, exhaust gas/dust collection, exhaust air purification, cranes, filter technology, building equipment (TGA): transformer station, hall ventilation, heating; automation, interlinking