New Stapelfeld Waste-to-Energy Plant:

SAR Implements Comprehensive EMSR and Control Systems

In 2021, SAR was commissioned by EEW Energy from Waste GmbH to implement Lot 3 (EMSR systems) for the replacement construction of the waste-to-energy plant in Stapelfeld near Hamburg.

The “New Stapelfeld Waste-to-Energy Plant” project encompasses the complete electrical infrastructure—from the 30 kV level down to the 24 V supply—as well as the entire control and building systems. This includes, among other things, lighting, telecommunications, video surveillance, emergency lighting systems, and the integration of the ventilation and air conditioning systems into the process control system. In addition, SAR, as a subcontractor to Standardkessel Baumgarte GmbH, supplied the fire power control system, which was fully integrated into the control system.

The new plant replaces the existing facility, which generated approximately 119,000 MWh of electricity and 228,000 MWh of district heating annually until mid-2025. The replacement plant achieves a significant increase in efficiency: district heating capacity can be increased to up to 400,000 MWh, while electricity production more than doubles.

Comprehensive system integration from a single source

SAR was responsible for the engineering, delivery, commissioning, and optimization of all systems in the project.
In collaboration with partner companies, the cabling and electrical installation were also fully implemented.

Key scope of supply includes:

PCS7 control system with high-availability architecture
Medium- and low-voltage switchgear
Transformers up to 45 MVA
Drive technology up to 2000 kVA
Comprehensive measurement and emission monitoring technology
Fire alarm, video, and security systems

Overview of the project scope and technical specifications

The scale of the project is also evident in the scope of the installation:

The Profinet systems include, among other things, 95 Simocode motor controllers, 43 ABB variable frequency drives, and 140 Auma actuators with redundant MRP connectivity.
In addition, ET200SP HA stations process over 1,200 analog, 5,200 digital, and 500 safety-related signals, and 90 control cabinets and sub-distribution panels were designed, delivered, and installed.

Over 290 km of cable, approximately 1,700 lights, and more than 50,000 man-hours were completed over a project duration of more than five years.
With its successful contribution to the Stapelfeld waste-to-energy plant, SAR once again underscores its expertise in the implementation of complex energy and industrial projects.

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