Where quality saves lives

Technology developed by WATZ Hydraulik in action against chemical weapons

Chemical warfare ranks as the most dangerous, the most deadly and the most feared method of waging war. At the end of Word War II, the use of chemical and biological weapons was prohibited by the international community. Since then, aside from the numerous violations that have occurred despite this decree, mankind has had to deal with another, similarly important issue:  What to do with the chemical weapons that already exist? These arsenals of doom harbour a great potential of danger in more ways than one. Their use on humanity is of course the primary risk. However, the improper storage of such weapons is no less dangerous. Environmental catastrophes of unimaginable scale loom on the horizon. Large caches of chemical weapons are still in storage across Eastern Europe and the former Soviet Union. In 2006, several German companies helped to establish special facilities for the demolition of chemical weaponry in the Russian cities of Kambarka and Potchep. Each of these plants prepares up to 1,000 kg/h of reactive matter for incineration. Special technology provide by WATZ is in operation at both plants. The Stuttgart-based company Eisenmann AG is known to be the worldÙs leading system supplier of surface, environment and process technology. Their expertise in constructing facilities for exhaust air and waste water treatment and, in particular, thermal recycling and disposal of waste materials, is of primary importance in the disposal of chemical weapons. For these aforementioned applications, Eisenmann supplies a variety of technically sophisticated components, including explosion chambers, state-of-the-art robotics for transporting chemical warfare agents and special ovens in which nerve gas is safely incinerated. Many of these plants also feature components supplied by WATZ Hydraulik. In this field, the smallest error can lead to great catastrophe. The companies charged with the demolition of these weapons and the manufacturers of the machinery in use therefore rely only on those components suppliers able to guarantee the highest-possible product quality. That is why Eisenmann relies on hydraulics products made by WATZ Hydraulik. Due to the very special circumstances of the project, WATZ was integrated in the planning and construction phases from the very start. Working closely with Eisenmanns development department, WATZ was able to develop optimum solutions for this highly sensitive area of application. WATZ provided the entire hydraulics station for the shuttle kiln. The power unit, installed on a special platform, was charged with opening and closing the shuttle kilns lift gates, which weigh some 18,000 kilograms. Each lift gate is operated by a separate power unit. To ensure operating safety, the power units are switched to the alternate lift gate.
   

    The lift gates themselves are raised and lowered by a special chain hoist. When lowered, the lift gate touches down on special rollers and is then pulled up to the furnace chamber by way of additional horizontally installed, unidirectional cylinders. This towing action must occur under a specifically predetermined amount of pressure, as the incineration process can potentially cause an increase in pressure of up to +300 mbar. Special safety valves prevent excess pressure inside the chamber. Furthermore, pressure reservoirs have been integrated to prevent pressure peaks. In the very unlikely event of hydraulic system failure, full closure of the lift gates is nevertheless guaranteed. Moreover, the gates are also protected against sudden collapse caused by an unforeseen loss of pressure, as it is possible to open only one gate while the system is in operation.

    With all of these measures in place, this WATZ system is able to guarantee maximum operational safety. Not bad for an application that is in use 350 days a year, with three shifts per day! WATZ technicians were naturally on hand during system start-up and visit the site regularly for service and maintenance calls. System documentation was made available to the client in Russian, English and German

Pictures: Eisenmann AG

DEMOLITION OF CHEMICAL WEAPONARY