Material recycling and safe use for district heat production in Vatajankoski

When the Kankaanpää district heating plant in Vatajankoski switched from peat to wood-based fuel, a need to develop the processing of bedding material emerged. The recycling solution supplied by Kopar helped to reduce material waste, improve occupational safety and support the plant's sustainable energy production goals.

About Vatajankoski Oy

Vatajankoski Oy is a Finnish energy company that produces district heat, electricity and industrial steam, with a strong focus on sustainable and responsible energy production. The company aims to reduce the use of fossil fuels, reduce emissions and develop its operations in a more energy-efficient direction.

Starting point: fuel change brought new challenges 

The switch to wood-based fuel changed the operating conditions of the boiler. As a result of this change, the bed material of the boiler started to sinter. Vatajankoski needed a solution to remove the sintered lumps and recycle the material back into the boiler without having to replace it in large quantities.

The aim was:

The solution was expected to provide long-term support for the plant and to adapt to changing operating conditions.

Implementation: a jointly built package

When searching for alternatives to bedding material, the bedding sand was replaced by granules. At the same time, Vatajankoski chose Kopar to supply a system to separate the lumps and excess fines and return the good material back to the boiler.

Granules are made of blast furnace slag of the steel industry, offering a more durable alternative to traditional furnace sand used in fluidised bed boilers.
Kopar provided Vatajankoski with a complete solution for the recycling of bedding material. The delivery included the supply, installation and commissioning of the system, and it was carried out during the spring and summer of 2023.

The limited space available at the plant imposed constraints on the solution, which meant that compromises had to be made at the implementation stage. This underlined the importance of close cooperation at all stages of the project.

Kopar's delivery included:

Commissioning and lessons learnt along the way

The implementation of the new solution was not without its problems. The first winter season proved challenging, and the system had to be developed and adjusted based on practical experience.

During the project, a lot of development work was done by both Kopar and Vatajankoski. The solution was adapted to better match the actual operating conditions, and as experience was gained, the system evolved significantly from the original.

The result: a better everyday life and better usability

Currently, the solution is working as designed and supports the daily operation of the plant. The recycling of bedding material has become part of normal operations, and the manual steps previously associated with handling hot material have been eliminated.

Even a single unnecessary shutdown avoided will bring significant savings, and the investment will support the reliable and safe operation of the plant in the long term.

Service and maintenance as part of the whole

During and after the project, Kopar's service team has been closely involved in supporting the operation of the facility. Spare parts and assistance have been provided quickly when needed, and the customer's experience has been that they have not been left on their own in case of problems.

Conclusions

The cooperation between Vatajankoski and Kopar shows that new solutions often require development work even after implementation. Open cooperation, practical problem solving and effective maintenance are key to achieving a long-lasting and reliable result.

Do you want to develop material recycling in your own facility?

Contact Kopar's experts to discuss how to develop bulk material handling both safely and cost-effectively.