2 Renewable energiesEngineering-Times PÖRNER GROUPOn schedule: Bioethanol plant likely to set recordsGENERAL PLANNING. Pörner implements largest projectin its company historyVIENNA (Gerhard Vlcek). Thenew bioethanol plant in Pischelsdorf/LowerAustria beingimplemented by Pörner as generalengineering contractor forAGRANA Bioethanol GmbH onthe banks of the Danube river,is another example for efficientengineering work in large-scaleprojects. With an overall investmentvalue of EUR 125 millionthis plant is the biggest industrialplant being built in Austriaat present – and the largestproject in Pörner history.Flexible use with differentraw materialsThe annual plant capacity willbe up to 240,000 m 3 (190,000 t)bioethanol. Feeding stuff DDGS(Dried Distillers Grain with Solubles)is produced as importantby-product. The main feedstockis grain, preferred wheat; whenrequired corn or thick sugarbeet juice can be used as well.The different feedstock can bedelivered by railway, truck orship. Bioethanol and feedingstuff are transported by railwayor truck – for legal reasonsshipment of bioethanol on theDanube river is not allowed atpresent.What is the best technology?During project developmentPörner assisted the client in selectingthe plant location andthe process based on whichbioethanol is produced. Afterhaving thoroughly weighed uppros and cons of different technologiesand after a detailedfeasibility study had been preparedby the client, the processof the American technologyprovider KATZEN InternationalInc. was finally chosen.Notification on EIA quicklyobtainedOnly two months after havingselected the process, the authorityapproval procedure acc.to the EIA Directive could beinitiated. In close cooperationwith the licensor, AGRANAspecialists and independent experts,Pörner prepared the documentationfor the extensiveauthority approval procedurefor EIA before very long.Not even seven months later,i. e. in June 2006, a legally validnotification for the implementationof the plant was obtained- in Austria most likely to setrecords as regards such kind ofindustrial plant.Upswing with drawbacksWhen the legally valid notificationwas obtained Pörnerstarted detail engineering andpreparation of tender documentsfor plant components,summoning all available engineeringresources. What madea quick project implementationmore difficult was the fact thatthe raw material prices for steel,copper and different equipmentparts went up enormouslywithin a short time. In additionto this, difficulties in searchingreliable vendors that offeredreasonable prices ocurred dueto the very good economic situation.The biggest challenge in thisproject was to place orders indue time to ensure completionof the project at the scheduleddate.Implementation atfull stretchSince July 2006 excavatorsand other building machineryhad been in use. Most of thecarcass work was completed inautumn 2006. Structural steelerection, erection of large vesselsas well as installation oftechnical equipment incl. pow-INFO-BOXTHE BIOETHANOL PLANT CONSISTS OF:Production plant• Raw material reception andstorage (silo unit)• Grain washing and milling• Mashing• Fermentation• Distillation and dehydration(alcohol drying)• Spent mash dehydrationand DDGS drying with palletizing• Spent mash evaporation unit• Ethanol storage and filling• DDGS storage and filling• Auxiliary material storage,chemicals storage and CIPsystemwell as site coordination servicesincl site supervision.Just-in-timeengineeringIn the end it should be mentionedthat this project can onlybe implemented by intensiveinterdisciplinary cooperationOff-sites• Washing water and processwater system• Cooling towers and coolingwater system• Fire water system• Compressed air station andsystem• Energy generating stationwith steam boiler and steamsystem• Transformers and powerdistribution system• Gas supply with gas throttlingstation• Control room and administrationfacilities• Internal road system/railwayfacilities and railsbetween all Pörner engineeringdepartments and specializedengineers of AGRANA BioethanolGmbH. The close link to theclient and the competence ofspecialized engineers allows forextremely efficient project implementationand almost ‘justin-time’engineering •180° panorama of the site in May 2007North-East South South-WestAerial view of the site in June 2007er supply facilities alreadystarted in winter2006/2007. In late May2007 basic installationwork and structuralsteel work were mostlycompleted, at presentpiping and cabling isbeing carried out atfull speed. After only15 months the plantwill be commissionedin autumn 2007.Planning from A to ZPörner is responsiblefor all engineering disciplinesup to commissioningof the plant.Roughly spoken theseare civil engineeringincl. structural analysis,structural engineeringincl. structuralanalysis, mechanicalequipment, packageunits, piping (pipingand valves incl. isometricdrawings of theplant), electrical andinstrumentation asPÖRNER BUDAPEST: BIOGAS PLANTA good start tothe new yearBUDAPEST (Judit Jonasne).Last year’s joint efforts and rethinkingthe sales directionshave paid off. Still in December2006 Pörner Budapestwas awarded anengineering contractfor a biogas plant inKaposvar/Hungaryby Magyar Cukor, thebiggest Hungariansugar producer. MagyarCukor is a subsidiaryof the AustrianAGRANA Group.The total investmentsum of this biogas plantwhich is unique of its kindamounts to EUR 6.2 million.The plant will produce100,000 m 3 STP/d biogas fromapprox. 800 t residual substancesthat remain after sugarbeet processing. The objectiveis to replace expensive naturalgas and to lower energy cost forsugar beet processing.The conceptualdesign was preparedin a very transparentand close cooperationwith the client,and in March 2007authority engineeringdocuments werehanded over. Everybodywas delightedthat the documentationgot authority approval atthe first attempt. The plant willbe commissioned in autumn2007 as scheduled. Pörner isoptimistic to get subsequent orders.•
PÖRNER GROUPBitumenEngineering-Times 3Bitumen Complete Solutions:BCS GROUPRevolution in a bagINNOVATION. Pörner is setting up the BituBag ® network.VIENNA (Andreas Pörner).Pörner knows almost everythingabout the stuff roads aremade of. Within the last decadesthe Pörner Group couldbuild up a good reputation asspecialist inb i t u m e ntechnolog yon internationalscale.B i t u m e nplants havebeen implementedon allcontinents:more than35 plants intotal all overthe world.The BituBag ®After cementbitumenis the most important buildingmaterial. Especially in times ofan international boom, more,better and wider roads are builteverywhere. The world-widedemand for bitumen increasesenormously. However, and thisis paradox, less and less bitumenis produced: refineriesignore the “dirty” part of theirproduction. They want to crackheavy crude oils into fuels.Therefore, up to 20 million t/abitumen will be missing in thefuture, estimating the presentproduction in the world at 100million tonnes.Pörner offers a way out of thisdilemma. Using the Biturox ®technology, bitumen producerscan yield more and better bitumenbased on the same feedstock.Another idea is to buildspecial bitumen mini-refineriesthat process the unloved heavyoils into bitumen.Consulting award for PörnerThe BituBag ® system is Pörner’slatest innovation to improve thebitumen situation in the world.This system consists of a coolingand packing unit, the reasonablypriced, flexible plasticbag “BituBag” itself which isdesigned for up to one tonne bitumen,and a melting unit. Allthree elements together makeup a complete system for bitumenlogistics.Due to bitumen supply shortagethe international tradeand, thus, the intercontinentaltransport becomes more andmore important. With the Bitu-Bag ® system Pörner has developeda completely new solutionThe BituBag ® can be shippedby any means of transportation.allowing for transport of largebitumen quantities in cold conditionand by common meansof transport (truck, container,ship). With these three approachesPörner wants to makea contribution to provide tenpercent more bitumen all overthe world.Foundation of BCS AGBased on the strategy to meetthe needs of the bitumen worldin a better way, the job wasproperly done on September26, 2007: a subsidiary, the BitumenComplete Solutions AG,was found. Through this companyand using the BituBag ®system a world-wide bitumennetwork for packing and logisticsshall be created.In the first six months of 2007joint ventures with local partnerswere established in Portugal,Singapore, Venezuela andthe Ukraine. Filling units andbags are also produced by subsidiariesthus ensuring a continuouslyhigh quality of the system.The objective of BCS is tolet the BituBag ® become worldstandard for packing quality.BCS AG started to act independentlyin June 2007 bysplitting it off from PörnerIngenieurgesellschaft. In theAndreas Pörner (CEO)Marcel Schuster (CFO)same month the capital was increasedand the BAST Group,an investor around Ms. BarbaraWösner-Sandberg and Dr.Stefan Zapotocky, both formerboard members of ViennaStock Exchange and BudapestStock Exchange, took a sharein the company. Thus, BCS hassufficient financial resources tointroduce the BituBag ® systemall over the world. In Augustthis year filling units will becommissioned in Portugal andSingapore.•BITUROX ® -OMVAn old lady retiresSCHWECHAT (Christian Opitz).After 40 years’ operation ofthe very first Biturox ® plant atOMV Refinery in Schwechatit was high time to replace it.In autumn 2004 Pörner wasawarded the contract for extendedbasic engineering byOMV in order to carry out thismodernization.The objective of the projectmainly was a continuous productionof industrial bitumen90/10. The old plant was notdesigned for it and could notmeet the increased productionrequirements any longer. Sincerehabilitation was not reasonablefor economic reasons, OMVdecided to set up a new plant.Planning began in June 2005with the intention to commissionthe plant in summer2006.In early September thebuilding work already started.Detail engineering was a challengefor all parties involvedsince at the small site a plantclearly laid out and easy to operate– that was a very importantfact for the client - shouldbe built.In spring time the hot phaseof equipment and piping installationcould begin. Up to100 skilled workers were at thevery confined site at the sametime. But safety first: Untilcompletion of all work no accidenthappened!The ‘blockbuster’ in roadconstructionAfter the start-up tests hadbeen completed the plant wasfed with feedstock and processair for the first time. Asnot expected otherwise, theperformance test was fulfilledat the first attempt. The relativelysmooth implementationof this project was mainly basedon the long-standing, goodThe new Biturox ® plant at theOMV refinery in Schwechat, Austriacooperation betweenOMV andPörner as well asvendors and installationcompaniesinvolved.The producedbitumen 90/10is not only neededin the form ofmastic asphaltin the market,but also servesas blendingcomponent inthe productionof polymer modifiedbitumen. •BITUROX ® -NIZHNEKAMSKMore bitumen for RussiaVIENNA (ChristianOpitz). When thewhole refinery inNizhnekamsk/Tartastanwas taken overby TAIF from Tatneftoil company, the situationwas not easy forPörner, since Pörner,Vienna was involvedin the preparation ofbasic engineering fora Biturox ® plant toproduce road, industrialand roofing feltbitumen at that time.However, only a short analysiswas required and in February2006 the new owner, TAIFplaced the order for detail engineeringand delivery of equipmentwith Pörner.Engineering of theengineeringThe decision on the constructionof the unit was linked witha reduction of the initial overallcapacity. Therefore, the basicengineering of the two-reactorunit with a design capacity oftwo times 120,000 t/a bitumenhad to be re-engineered.The unit had to be adapted tothe area of the existing vacuumunit for which Pörner took overall engineering work.Effective implementationDuring project implementationa reliable Russian engineeringpartner, but mainly also theinvolved Gazintek specialistsknowing the language considerablyhelped – an examplepointing the way towards involvementof subsidiaries withinthe Pörner Group.After a very short constructionand installation period,assisted by the good work ofthe procurement and logisticsdepartment in Vienna as wellas a relatively mild winter inRussia (only a few days colderthan 30 °C below zero), the firstconstruction stage could becommissioned after less thanone year.The key products – bitumen70/90 and 90/130 which areimportant for local road construction– were immediatelyachieved.•
4 Eastern EuropeEngineering-Times PÖRNER GROUPGrowth of Pörner Group continuesSTART-UP. Pörner strengthens presence inCentral Eastern Europe with a new office in Romania.BUCHAREST (Michael Volkmann).Not only since its joiningthe European Union in January2007 has Romania been an interestingmarket for the PörnerGroup. At an annual economicgrowth rate of almost eight percent,the Balkan state has beenone of the most dynamic regionsin Europe over the last years. Itis remarkable, that comparativelysmall Austria – not onlythrough the take-over of thelocal oil company PETROM bythe Austrian OMV Group – continuesto be the largest foreigninvestor in Romania. Pörnerhas recognized this opportunityand expanded its networkof medium-sized engineeringoffices by establishing a registeredoffice in Romania.With Michael Volkmann andEmanuel Racanel at the helm,it is the declared goal to buildup strong competence in processtechnology and, paired withproject execution know-how,local know-how and synergieswithin the Pörner Group, to increasePörner’s edge for betterservice out of Romania to clientsworldwide.On June 26, 2007 the officialinauguration of the latest Pörneroffice was celebrated. Morethan 60 business partnersfound their way to the office inPloiesti. While spending an unforgettableevening with classicmusic and dance, new contactswere made and future projectstalked over.On track immediatelyOperation Romania commencedback in January 2006,when Pörner was awarded thefirst substantial contract. In astudy of the existing tank farmsin Arpechim and Ploiesti, thecondition of some 1,000 tankswas evaluated, and a comprehensiveproposal for the logisticoptimization of the tank farmmade. The study included substantialsite investigations andtook nine months to complete.Besides the intensive and successfulwork on the study, thetime was also used to preparethe local set-up of the new company.It was in November 2006 thatthe official registration of the„S.C. POERNER EngineeringServices S.R.L.“ with its administrativecentre in Bucharesttook place. The operationaloffice is located in Ploiesti, thehistorical centre of the oil- andgas-industry.We offer “The Lot”Within short the Ploiesti officeis planned to provide work forsome 25 employees. The fieldof expertise will cover processtechnology, machines / apparatus,piping, electric, controland instrumentation and civilengineering. Pörner has at itsdisposal a motivated team, experiencednot only at the localfront but also in traditional Romanianmarket territories suchas Syria, Iran, Iraq, Egypt andIndia.After only a short period ofsetting up business, Pörner wasin a position to offer a comprehensivepackage in the fieldsof plant building for refinery,petrochemistry and specialchemistry plants. The possiblescope of work ranges from pureengineering services to turnkey construction. One of thebig assets of the Romanian officeis the detailed knowledge ofRomanian technical standards,laws and regulations.OutlookA current project concerns thedesign of an atmospheric vacuumdistillation, the heart ofeach refinery. In the course ofthe basic engineering, the complexplant model was digitallysimulated and optimized. Thisprocedure provides the clientwith the best possible securityin terms of optimal design ofthe components and efficiencyof the entire plant.There are considerable businessopportunities in the fieldof renewable energy sources.The list of planned investmentsin this field is significant. Fromday one Pörner Romania hasoffered the full range of servicesfor these undertakings, fromidentifying and providing thenecessary preconditions for thereceiving of EU subsidies to thetimely provision of the authorityengineering – all of whichunder due consideration of thepertinent laws and regulationsand in close cooperation withthe local authorities.The experience and competenceof the local employees of PörnerRomania matches internationalstandards. Their expertise isa further synergy that is nowavailable for the benefit of theentire Pörner Group. •General Manager RomaniaMichael Volkmann (r.) andEmanuel Racanel (l.) at thenew office in PloiestiBine ati venit in RomaniaWELCOME TO ROMANIARomania, a state of 22 million inhabitants,is linguistically a Romanic island,surrounded by Bulgaria in thesouth, theUkraine inthe east andHungary inthe west.For the lastfive years,Romania has enjoyed sound economicalgrowth. In 2006 the growthrate amounted to 7.9%. This growthcan, if anything, be hampered by thestill inadequate infrastructure - Romania’shighway net is a mere 200Festive inauguration of the officein Ploiesti on June 26, 2007km, the rest makes driving “an experience”.A certain analogy to thetimes of the gold rush can be felt andexperienced in Romania especiallyin three-million-people Bucharest.Limiting ones perception of Romaniato Count Dracula (and the correspondingconsumption of garlic)does the country no justice. Sibiu,the largest city of Transylvania, forexample, has been appointed the EUCultural Capital of 2007. The prettytown intrigues by its middle agecharm and the outstanding beautyof its surrounding countryside. Alsothe pristine mountain stretch of theCarpathians, the natural paradiseof the Danube delta or the 245 kmof Black Sea beaches elate the stillfew visitors. Romania has yet beenspared of mass tourism. Thosewanting to experience the land ofthe Carpathians in its true fashionhad better be quick, though.KIEV (Albert Traxler). At theturn of the year 2006 Pörnertook the decision to acquire theremaining 30 percent shareson Gazintek. As sole owner,Pörner intends to strengthen itsposition in the Central EasternEurope region and increase itsmarket share. The acquisitionenables Pörner to increase flexibilityin the strategic planning,resulting in a further advance ofGazintek as a leading specialistfor the design and constructionof gas related plants.Strong demand for engineeringservices in CEEDespite the current politicalturbulences the Ukrainianeconomy has to cope with,the economic outlook on theUkraine over the years to comeis promising. Demandfor engineeringservices increasesunabated.On the one hand,the Ukrainian andRussian industryrequire substantialrevamping oftheir productionplants to increasedproductivity andto reach and adhere to ecologicalstandards. On the otherhand, the Ukraine is confrontedwith a diminishing numberof engineers. Therefore a largePörner acquires 100% ofGazintek in KievEXPANSION. Boost for the developmentof the Ukrainian ventureand lasting amount of workneeds to be achieved. The bigchallenge is to be able to secureadequate human resources forthe tasks at hand. Gazintek hasformulated as one of its goals,to focus on increased trainingof present employees andthe recruitment and trainingof new employees. As a firstresult, eight new employeesjoined the team in 2006, withmore to come.Increasing quality andcapacityNot only the human resourcesaspect has been addressed, butalso technological matters. Newsoftware such as Smart Planthas been implemented, andnew technologies adopted. Thepleasing result of these effortsOur team in Kiev.was increased productivity athigher quality. Gazintek has increasedboth the range of servicesand the number of satisfiedclients. Follow-on orders fromPÖRNER GROUPclients far outside Gazintek’sclassic market, the GUS region,attest for the trust clients havein Gazintek’s expertise.Orders for securing works onthe Chernobyl-Nuclear-Plantand the complete design of anoxygen plant in Alchevsk arefurther proof for the fine strategicdirection Gazintek has takentogether with Pörner.Together we are strongAlready in the past, the Ukrainian-Austriancooperation hasproved successful. The expertknowledge of Gazintek’s engineersin the field of GUS/Russianstandards and regulationswas utilized for the benefit ofPörner’s Biturox ® -Project inNizhnekamsk/Russia. Alsoat other projects in Austria,Gazintek engineershelped outto cover peaks andthus contributingconsiderably to theprogress of the design.The Ukrainiansspent severalmonths in Vienna,getting more acquaintednot onlywith Pörner Vienna,but also with Austriaand its people. “Let us continuethis fruitful cooperation so thatsoon there will be only connectionsinstead of borders.” •Parliament “House of people” in Bucharest, the secondlargest building in the world after the Pentagon.
PÖRNER GROUPMade in GermanyEngineering-Times 5Wasteless to recycled base oilsEXPANSION. Basic engineering for HyLube 2 plant completedPÖRNER GROUPLEIPZIG (Matthias Haring). Bysigning the contract for detailengineering services betweenPuralube GmbH located in Elsteraue/Germanyand EDL thebasic engineering stage ofthe HyLube 2 plant was officiallycompleted. Over the lasttwelve months the conditionsfor performing the next stagehave been provided based onthe UOP HyLube process.It was important to integrateowner’s knowledge gainedduring operation of the firstplant as well as modificationsto the UOP process design intothe basic engineering.This continuous process inwhich waste oil is contactedwith heated hydrogen gas by directcontact hydrogenation is atechnology implemented in theworld for the first time.The principle of the processis to evaporate waste oil whichis then separated from unevaporatedsubstances and strippedin a vacuum column. Inthe subsequent hydrogenationstages contaminantes that wereinitially brought into the lubeoils through additives are separated.These contaminantes areneutralized and led into a twostagewaste-water treatmentunit. The hydrogen gas is cycled,spent hydrogen is replacedby make-up hydrogen. Theliquid phase is fractionated,and base oils with differentviscosity are produced in thisstage. Only small quantitiesof naphtha and gasoil are producedas by-products so thatthe process can be consideredalmost wasteless.The second plant of thiskind is being implementeduntil September 2008. Thehydraulic design is 80,000t/a , i.e. on the same level as theexisting plant. EDL is preparingthe detail engineering andtender as well as ordering documents.The Puralube Groupwill be responsible for procurementas well as constructionservices.•Managing Directors Andreas Schüppel (Puralube)and Gerhard Moser (EDL),in May 2007 during the signing of the contractat EDL in Leipzig, Germany.LEUNA HARZEThe success storygoes onLEUNA (Conrad Wagner). Sincespring 2006 EDL has workedon possibilities to increaseproduction of reactive dilutingagents at Leuna Harze GmbHby building a new plant and prepareda study. At that time the‘Leuna Harze 3’ project was beingimplemented at full speed.In December 2006 the clientmade a decision and placed anorder with EDL for the secondglycidic ether plant long beforethe Leuna Harze 3 plant wascompleted.The new plant for productionof synthetic basic resins(Leuna Harze 3 plant) havingan investment value of approximatelyEUR 25 millionwas engineered, implementedby EDL within 13 monthsand handed over to the clientat the end of March 2007 asscheduled. Thus the annualproduction capacity at Leuna-Harze GmbH and its subsidiaryLeuna-Epilox GmbH wasincreased to approximately40,000 tonnes liquid epoxyresins. Now, the successful jobin Leuna continues.An order with consequencesThe minutes of meeting on mechanicalcompletion of the epoxyresin plant had just been signedwhen the next order was placed:planning and erection of anotherbisphenol F plant. EDL could alreadygain experience in this fieldin 2004 and 2005 when settingup the first bisphenol F plant.With an investment value of approximatelyEUR 10 million thenew plant will be slightly smallerthan the basic resin plants, however,it is highly innovative. Incomparison to its older ‘sister’ itwill apply advanced technology.In twelve months the first productshall flow.Both new orders deliver proofof the high regard that EDLenjoys at the chemical site inLeuna and show the capabilityof the EDL staff.And who knows what otherchallenges are waiting for EDLengineers at Leuna-Harze … •PCK REFINERY SCHWEDTHighest building of PCK Refineryhanded over by EDLSCHWEDT (Horst Thalemann).On May 9, 2007 mechanicalcompletion was finishedon time and one of EDL’s biggestchallenges – the erectionof a C3 splitter (with 84 m thehighest building of the SchwedtRefinery) – was brought to asuccessful end. In August andSeptember 2006 a logistic masterpiecewas performed whenshipping and assembling thecolumn (we informed about itin our previous issue). Now allPÖRNER GRIMMA: SILICON PLANTGlobal change in climate concerns all of us ...works to complete the plant,particularly services during thetwenty days’ shutdown period,could be executed by the agreeddeadline – despite tight deliveries.Reliable partnershipWith its very committed andprofessionally working projectteam EDL has shown once againthat it is more than justified toenjoy PCK’s long-standing confidence.•GRIMMA (Dieter Nowak). …and not only since the last politicianwas shaken up and dedicatedhimself to this issue.A few years ago solar technologywas still smiled at. Todayit is a rapidly spreading technology.From solar watchesthrough cableless garden lightsup to solar power stations withcapacities of up to 5 MW – thereis a wide range of applications.Over the last years more andmore solar cell producers haveentered the market expandingby 25 – 35 % per year worldwide.And silicon, the main rawmaterial, is running short.The following article publishedin Mitteldeutsche Zeitungof May 8, 2007 goes with thisissue.This is not only good news forthe Chemical Park Bitterfeld-Wolfen, but also for Pörner.Since October 2006 PörnerGrimma has assisted PV SiliconAG in adjusting the processfor solar silicon production andits technical implementation.From October till December2006 a pre-basic design forhydrogenation and separationunits was prepared. Since January2007, together with PVSilicon AG we have been workingon the basic engineeringof the technological ‘heart’ ofthe plant. This work will becompleted in June. Then detailengineering and implementationplanning will follow – tobe jointly prepared with PlanungsbüroRohling AG andRuffert & Partner that will beresponsible for constructionand HVAC of the reactor buildingand adjacent buildings.The new plant will be combinedwith an existing plantof Degussa AG in Bitterfeld.That means, the required rawmaterials will be provided byDegussa and resulting by-productswill be led back to Degussato be recycled and partiallyreturned to the process cycle.These fringe conditions andassociated subsidies grantedby the state Saxony-Anhalt, theFederal Government and theEuropean Union make this locationattractive to build such aplant also in Central Germany.•
6 Pörner InternationalEngineering-Times PÖRNER GROUPTruffles, mushrooms, and the JapaneseFOOD. Implementation of a fungiculture plant near Vienna by Pörner KundlKUNDL (Martin Embacher).When inFebruary 2005the phone rangin Kundl/Tiroland the questionwas raisedif we were interestedin implementingafungiculture planttogether withPörner + Partnerfor the Edlinger company,no one couldimage what it shouldbe. However, it turnedout to be a humorousproject since pure mention ofthe project produced a smile ineveryone’s face as if by magic.And further on we were askedagain and again how thingswere with the mushrooms.The mushrooms were mainlyoyster mushrooms and shiitake,other sorts are planned. Itis almost a miracle to be able tocultivate even truffles. In thiscase, the hotbed is filled in bagsand after incubation put in thefield. Where this field is located,is though top secret, and Mr.Edlinger did not want to tell anyone,not even us.“Mushrooms look forthe way out”The cultivation process isspecial and unique becausemushrooms are cultivatedin bottles. The process wasdeveloped in Japanand has been spreadthere for more thanten years.The bottles are filledwith a special mixtureof single-varietyoak and beech chips.Germs are then eliminatedin a sterilizer.When the bottlescome out of the sterilizer,they still have atemperature of 80 – 90°C and are then cooled toapproximately 20 °C incooling chambers. In thenext stage, the so-calledmycelium is brought intothe bottles. This is donealmost under cleanroomconditions in order to inoculateonly the requiredspores. Then the bottlesare put in an incubation chamberto let the mushrooms grow.There, depending on the sortof mushroom and under veryspecific temperature, light andhumidity conditions, it takesbetween six weeks and threemonths until the mushroomshave used up the hotbed.When all the hotbed is usedup, the spore’s last way out isto breed. It starts to put fortha mushroom as we know andeat it. At this stage the bottlesare sent to the cultivation areawhere the mushrooms can bepicked up. After having beenharvested the mushrooms aresorted and prepared for dispatch.Biomass remaining inthe bottles is scrapped out andfurther used as fertilizer.A small power stationThe plant in the Marchfeldnear Vienna is designedfor an annual capacityof approximately350 tonnes, i.e. approx.one tonne per day. Sinceduring the growth ofthe mushrooms heat isreleased to the environment,both incubationand cultivation areashave to be cooled continuously.If one takes into considerationthat about600,000 bottles are storedin the incubationarea laid out as a highlevelstorage and eachbottle releases about 0.18W, the resulting internalcooling load amounts tomore than 100 kW – a miniaturethermal power station. Dueto this fact, energy consumptionis very high since steamis required for sterilization. Asteam boiler with a capacity of1.3 tonnes steam per hour wasinstalled.Furthermore about 900 fluorescentlamps were installedto provide the mushrooms withenough light for growing.Sunrise over MarchfeldThe contact with Japanese designersand scientists that cameto the Marchfeld for meetingsat regular intervals was a niceexperience. It required a greatdeal of sensivity to filter the Japanese-Englishlanguage mixtureso that the requirementscould be finally agreed on. Theengineering had to be done ina similarly flexible way, sincebeside empiric data of similarplants there were no sound calculations.However, we coulduse our experience gained fromprevious projects so that detailengineering was completed onemonth before construction andinstallation should start. In October2006 a wonderfully workingfungiculture plant could becommissioned.The first mushrooms producedin ‘our plant’ could alreadybe tried – they are of an excellentquality and taste. •BUDAPEST (Lutz Hoffmann).Pörner Budapest has succeededin creating a solid basis for astable utilization of its capacitiesin the long run by settingup its own, experiencedPDMS team. In January2007 a long-term contractfor engineering services wassigned with MDR EngineeringGmbH located in Bitterfeld/Germany.By providingengineering services PörnerBudapest supports and extendsPDMS piping designcapacities in the field of powerplant piping engineering.Pörner Budapest is going toPÖRNER LINZ: IMPLEMENTATION OF A TANK FARMFor all animals great an smallLINZ (Eugen Gotter). PörnerLinz was awarded a contractfor general planningof a molassesand vitaminE tank farm includingassociatedinfrastructuresby SchaumannGmbH &Co. KG. This globallyacting companywith a longtradition runsa production inTaufkirchen / Upper Austriato produce efficient nutritionalsupplements for animals andspecial animal feeding stuff.The scope of work to be performedby Pörner Linz includedthe following:• preparation and updatingof piping and instrumentationdiagrams withprocess description• layout planning, detail andimplementation planning• permit engineering• construction guid-PÖRNER BUDAPEST: PLANT ENGINEERINGSuccessful with PDMS-3Dfurther increase its existingcapacities in the field of PDMS-3D piping engineering. Alreadyin February two employees gotintensive training in Bitterfeld,ance planning• preparation of inquiryspecifications• comparison of quotationsand suggestionsfor vendor selection• site supervision as well as• documentationPörner Linz is goingto finish theproject withinnine months.Completion isscheduled for November2007. •another three PDMS engineersshall be added to the very motivatedteam. “We have highlyqualified engineers with verygood knowledge of languagesin Hungary. MDR is verysatisfied with the job our engineersdid”, says Judit Jonasne,head of the Budapestbranch office.The PDMS know-how theBudapest engineers havewill be made available to thewhole Pörner Group in thenear future. It goes withoutsaying that complete packagescan be engineered in Budapest,too.•CLEANROOM TECHNOLOGY AT FIRST HANDWORKSHOP BY PÖRNER KUNDLKUNDL (Lydia Barth). Morethan 30 companies took partin the cleanroom workshop inKundl. They learned all basicsof cleanroom technology/GMP.Together with KompetenzzentrumMedizin Tirol (KMT) andVTU Engineering a cleanroomworkshop was held at SandozGmbH in December 2006.“More than 30 participantsfollowed the call to Kundl. Excitinglectures and two specialguided tours gave the opportunityto learn under more or lessreal conditions”, recapitulatedMartin Embacher, newly appointedhead of Pörner Kundlat the successful workshop.No alternative to cleanroomtechnologyToday one cannot imaginemedical technology, biotechnologyand pharmaceuticalproduction without cleanrooms.“There is often no alternativeto cleanroom production.On the one hand it isrequired by legislation throughbinding regulations such aslaws on pharmaceuticals andmedical products, on the otherhand it is required by the customerthrough quality standards”,stated Embacher.Qualification know-how byPörnerThe Pörner lecture offeredthe participants an insightinto the wide range of requalificationand revalidationof cleanrooms. Martin Embacherand Alois Kronthaler informedabout the basic qualifyingprocedures. It is importantto define and record all qualityrelateddata. Then they have tobe evaluated, deviations haveto be commented on. “In caseof a re-qualification the rightconclusions have to be drawnand appropriate measures betaken”, explained Kronthaler.Cleanroom technology inpractical testThe workshop was organizedunder the REGplus site initiativeof Tirol Impuls and CompetenceCentres. Many thanksto the Sandoz managementthat offered the location to holdthe workshop and organizedspecial guided tours throughcleanroom production.Because of the fact that 84%of the participants assessedthe workshop as “very good”and showed an extremely highinterest in continuing suchworkshops to consolidate theirknowledge, there is no doubtthat Pörner Kundl intends tohave another one soon.Martin Embacher hasa ‘clean record’.
PÖRNER GROUPMiscellaneousEngineering-Times 7VIENNA (Peter Schlossnikel).From April 28, 2007 to May 5,2007, the European EngineeringChallenge Cup was battledin Turkey. It was the engineeringbusiness’s 14th Cup.A record field of 70 sailingteams from all over Europe participatedin the regatta in thebay of Fethyie/Turkey. Startingand finishing point was the bayaround the picturesque town ofGöcek.Pörner crew in the leadNext to the big players of globallyacting engineering andplant building enterprisesof the likes of Jacobs, Lurgi,Uhde, Forster Wheeler, ABB,etc. also the Pörner Group wasThe Who is Who in engineeringHIGH-SEAS-SAILING. Pörner/EDL winner of the Commodore’s Cup.represented with one crew.Directed by their experiencedskipper Eugen Gotter of Linz,the Pörner/EDL team foughtbravely and very successfullyin the six races across Turkishwaters. In the end they finishedan overall 11 th - a truly outstandingresult.Double victory for PörnerThat was only half of the fare:Day four brought about thehighlight of the ECC 2007.Team Pörner was not only victoriousin the day’s regatta, butwrapped up the Double by alsowinning the “Commodore’sCup 2007”. This Best of theBest Cup is run every year betweenwinners of regattas in thepast 14 years. The Best of theBest now had a name: Pörner.In the presentation ceremony,the crew of six was adornedwith their well deserved doublegold medals for regatta andCup victory, as well as awardedthe yearly challenge cup.The victory for the overallevent went to the Dutch crewof “Hertel BV”, who now hasthe honor to organize nextyear’s ECC. Besides the honor,they have earned themselves ayear’s full time job. Who wantsmore information, results andpictures can have a look atwww.ecc-sailing.com. •That’s how winners look like!INSIDE REPORT OF TWO LIGHTWEIGHT SAILORS FROM LEIPZIGBy Wolfgang Kursch & LutzHoffmann. For the first time inhistory of the ECC the Pörnercrew was supported by twowould-be sailors from thehigh-flying sailing nation ofSaxony. No sooner had wegreenhorns entered the 15 mlong Bavaria 46 yacht, thanwe were introduced to themajor nautical terms andcommands. And we had tolearn fast: various maneuversat varying winds, varyingsail positions, countlessterminology and all too specialknots. Skipper Eugenalso impressed upon us thedangers of inappropriateconduct on board – heavywinds and banking wouldsoon teach us how importanthis instructions were.No sooner said than doneDisregarding the dangers, wehad trouble to keep our ambitionat bay – we longed tobe in the lead. In each of thefirst three races we finished aremarkable sixth. Thanks toour skipper Eugen, the crewlaunched first rate in each ofthe regattas, which earnedus top spots – an intriguingsportive achievement.The 4 th race: our victoryThe most exciting experienceOur team at the award ceremonyfor the Commodore’s Cup winners!was the fourth regatta, whichwould also be classed as theCommodore’s Cup. Againa fulminant start, we wereamong the leaders. Aftertwenty minutes the wind dieddown. Calm. Most of the fleetkept its oomph and passedus! We were left toidle in the calm.This kind of situationrequires specialkind of sailingdecisions. You have gotto take chances! SkipperEugen is our man for suchmoments. He inspired hissixth sense for wind andchose an entirely differentcourse. Literally sentfrom heaven the windpicked up, we launchedto full speed, and managedto overtake all competitors.In the end ourhealthy margin measured12 minutes. Yesss!Genoa and Radetzky-MarchEn route, our skipper didnot tire to give clear instructions:“celebrationsonly after the finish line”,“flowing sheets!”, “close-haulGenoa!”, “three man to thebow (as a ballast for weightbalance) and please don’t’ gooverboard!”. Naturally, wewere all smiles way before thefinish line. Our captain en terra,Peter Schlossnikel, was justas happy and proud of the successas the rest of the crew!Crossing the finish line, weblasted the Radetzky-Marchinto the air. It was our trademarkat each start and finishfor the days of the regatta.Proper attention was secured.All congratulateOur impressive victory waswell honored. Congratulationsarrived from all camps. Teamsfrom Holland, the Ukraine,Spain, Germany and the UKattended our modest party.All came to shake hands withour successful skipper.For all of us, these were unforgettableholidays. We wish theorganizers of next year’s ECCbest of luck and keep our fingerscrossed for an event justas exciting as this one. •VIENNA (Werner Gindl). Inearly 2007 the ORGANIKA 2production plant of DONAUCHEM HandelsgesellschaftmbH went on stream smoothly.Pörner Vienna was awardedthe general planning contractin January 2006 and was putin charge of the execution ofthe project. The scope of workincluded the preparation ofthe plant concept, authorityengineering as well as the basicdesign for equipment andmachinery, civil construction,sanitary and HVAC installations,electric, C&I and piping.At their plant in Pischelsdorf,Lower Austria, DON-AU CHEMIE mixes and preparesfor transport organic,inflammable fluids such asglass cleaners and anti-freezefluids. A view behind the wallsof the modest looking productionhall reveals a conglomerateof state of the art technology:the mixing facilities, fillingand packing lines, a highrack storage for empty casksand for packing material, twopallet high racks for the intermediatestorage of product(casks from 0.1 to 5 liters) anda truck-loading station – allfully integrated, working handin hand.Obviously, the engineeringrequired the strict adherencePÖRNER VIENNA: GENERAL PLANNER FOR DONAU CHEMFor clear sight when drivingto VEXAT and ATEX regulations,which ensure appropriatelevels of explosion-protectionin areas at risk. After all,given the hazardous nature ofthe products, the avoidance ofexposure enjoyed a high levelof priority so that the plant isoperable at minimal risk.For windshield cleaner and anti-freeze protection:3D simulation of the plant in Pischelsdorf, AustriaThe project team took onthis responsibility very conscientiouslyand managed thematter to the full satisfactionof the client. To live up to thechallenge of finishing the workwithin only ten months, demandeda great deal from theproject teams of both the clientand Pörner.Dedication pays off: In October2006 Pörner receivedthe follow-on order for “AN-ORGANIKA 3” from DONAUCHEM. Currently constructionis in full swing, but formore detail we shall wait untilthe project has been deliveredsuccessfully to the client. •