Kardex Mlog has restored to full fi tness the automated high-bay warehouse at the Essen facility of chemical company Evonik Goldschmidt. The main focus was on the facility’s controls and communication systems. The results were impressive, providing a high output with signifi cantly reduced operating costs.

Harald Bauer is head of the refurbishment division at Kardex Mlog, specialising in integrated control systems: “The control system, positioning devices, drives and plant visualisation system together form the heart of any facility”, is his opinion, based on experience of many

successfully completed refurbishment projects. “When it can no longer keep up with demand, a warehouse is simply no longer competitive.”

But it is not only the warehouse output that is adversely affected by outdated components, but also the environment

and the return on investment. There is an increasing cost awareness in relation to the issue of energy efficiency, since expenditure on energy is a major contributor to plant operating costs. Modern components enable energy consumption and CO2 emissions to be significantly reduced – thus reducing

New driving force for chemical productionRefurbishment at Evonik Goldschmidt

Project report

running costs, and once components are discontinued, software licences expire or maintenance and support services decline, then action must be taken to prevent plant downtime.

Two-phase refurbishment

Matters had not yet reached that critical stage at the Evonik Goldschmidt GmbH automated high-bay warehouse in Essen, the industrial centre of the Ruhr district. However, several of the integrated components of the storage and retrieval machines had already been discontinued, so a refurbishment schedule was devised together with Kardex Mlog and was implemented during ongoing operations.

The refurbishment work initially extended over a period of six months and focused on five out of a total of eight storage and retrieval machines. The refurbishment of the other three machines took place in a second phase – and the positive results meant that this was also done by Kardex Mlog.

Specifically, the existing S5 control systems were replaced by onboard S7

PLCs which replicate the control functionality of the old machines. Communication with the higher-level PLC now takes place via a Profibus-compliant ET200 module, and data transmission to the conveyor control system takes place via TCP/IP interface and WLAN. The specialists also installed contact-free laser distance measurement equipment. Monitoring is carried out via the new on-board camera systems which have a recorder function. This allows short video sequences to be recorded, and ensures rapid and problem-free fault analysis in the event of malfunction.

Sustainable refurbishment

The Evonik group emerged from RAG, the former parent company of the German coal industry. Evonik Goldschmidt is an international chemical business with over 1,400 employees at its Essen plant where speciality chemicals such as additives, stabilisers and emulsifiers are produced. These can be found in beauty products, detergents or paints and varnishes. For a group that also has its roots in the energy sector, sustainability and a responsible use of natural resources is a high priority.

Your contactfor this projectJochen KrüßmannPhone: +49 208 4683978-10Fax: +49 208 4683978-99jochen.kruessmann@kardex.com

Kardex Mlog refurbished the storage and retrieval machines at Evonik Goldschmidt’s Essen plant.

Kardex Mlog therefore paid particular attention to the improvement of energy efficiency during the refurbishment process. As far as the drive technology was concerned, the storage and retrieval machines were fitted with completely new systems. The motors of the traversing and lifting gear and the telescopic forks were replaced – as were the gears, wheels and rope drums. Only the existing telescopic forks and their associated sensors were retained.

The new drives are equipped with energy recovery technology. This ensures that during braking and lowering of the lifting carriage, energy released into the system can be recovered instead of being converted into useless heat. “The frequency control ensures that the drives have a higher level of efficiency and do not have to operate unnecessarily at full load”, stated Bauer, “combined with the energy recovery system this results in a noticeable reduction in costs to the budget and the environment”.

Visit www.kardex-mlog.com for detailed information.

Project report