Custom plant engineering with pneumatic conveying technology for bulk materials – from process development to turnkey plant
E.S.C.H. Engineering Service Center und Handel GmbH
07333 Unterwellenborn (Headquarters, production hall, pilot plant)New on Amplifa
About E.S.C.H. GmbH
E.S.C.H. GmbH, based in Unterwellenborn (Thuringia), was founded in 1992 from the research department of Maxhütte Unterwellenborn and specializes in the construction of custom and special-purpose plants as well as pneumatic conveying systems for powdered materials and granulates. The company develops and manufactures dosing, injection, adsorption and conveying systems for blast furnaces, converter and electric steelworks, aluminium smelting furnaces as well as power plants, the chemical industry and the food industry. Products include pulverized coal injection (PCI+), plastic injection (EKOFOR), dry flue gas cleaning (ESCHSORB), dosing of mold powder granulate (MULTIFLUX) as well as filter and homogenization floors. Every plant is individually calculated, designed and built; components are manufactured in the company's own production hall, subassemblies are pre-assembled, given corrosion protection and commissioned. A dedicated pilot plant enables research and testing services in mechanical, thermal and biological process engineering, including biogas and biochemical process engineering as well as ceramic membranes. The plants are erected at the customer's site and handed over turnkey, customer staff are trained, and after-sales service is guaranteed.
- Site
- Unterwellenborn
- Processes
- Pneumatic conveying technology / construction of conveying systems for powdered materials and, In-house component manufacturing, pre-assembly of subassemblies, corrosion protection, commissioning, Welding fabrication (certificate DIN EN ISO 3834, factory production control according to, Design and construction of biogas plants / biochemical process engineering including fermenter, FOS/TAC automatic analyzer – automatic online measurement with integrated sampling and sample, Fermentation and digestion tests at laboratory and pilot-plant scale, Mechanical process engineering: shredding, crushing, grinding, sieve and air classification,, Thermal treatment in rotary kiln and sinter pan
- Materials
- High-purity aluminium oxide (Al2O3 / alumina), Stainless steel (plant manufacturing), Ceramics (membranes, nanofilter membranes), Carbonaceous dusts / biochar / biogenic carbon carriers, Granulated coal, Coke ash, Graphite dust, Copper (granulate, chips)
- Certificates
- DIN EN ISO 9001, AMS – occupational safety with system, EN 1090 (factory production control conformity), DIN EN ISO 3834 (welding quality requirements), WHG specialist company (Federal Water Act), ISO 9001, EN 1090, ISO 3834, WHG specialist company
- Founded
- 1992
- Industries
- Iron and steel industry, Non-ferrous metallurgy, Chemical industry, Power plants, Food industry, Agriculture/Biogas
- 01
Process development and process analyses in the company's own pilot plant
- 02
Engineering and plant design
- 03
In-house component manufacturing
- 04
Pre-assembly of subassemblies
- 05
Corrosion protection and commissioning
- 06
Delivery, installation and turnkey handover
- 07
Training and after-sales service
Materials and processes
High-purity aluminium oxide (alumina)
Conveying and dosing of high-purity Al2O3, including in stainless steel plants for the chemical industry.
Carbonaceous dusts, biochar, biogenic carbon carriers
Used as reducing agents and supplementary fuels in conveying and injection systems.
Granulated coal, coke ash, graphite dust, coal dust
Conveying and dosing materials for blast furnace, gasification and cupola furnace applications.
Copper (granulate, chips)
Testing and injection trials for smelting reactors in non-ferrous metallurgy.
Ceramic membranes and nanofilter membranes
Manufacture of membranes and systems, including 3D-printed ones, for gas and wastewater treatment.
Wood pellets / wood dust from torrefied wood
Investigations into grindability, abrasion and pneumatic conveyability of biogenic fuels.
Lime, sand, iron ore
Mineral materials for dosing and injection systems, including in electric steelworks.
Titanium oxide carrier Rutilith
Mobile injection systems for injection into the tuyere zone of the blast furnace.
Magnesium wrought alloys
Processes for recycling-friendly processing of components made of magnesium wrought alloys.
Polyamide 6.6
Process development for the production of recyclable PA6.6 material from the waste tire fiber fraction.
Locations
Unterwellenborn
DEHeadquarters, production hall, pilot plant
- Materials
- Steel, stainless steel, aluminium, ceramics
- Pilot rotary kiln
- High-temperature chamber furnace (also with shielding gas purging)
- Sinter pan
- Biogas pilot plant (storage tank, fermenter, measurement station, PLC-controlled, PIMOS database)
- Test rig for gasification of solid fuels
- Test rig for pneumatic dense-phase conveying with natural gas and nitrogen control lines
- Mobile test rig for injecting copper chips and granulate
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Pneumatic conveying technology / construction of conveying systems for powdered materials andEngineering | – | – | – | – | Steel, Stainless steel, Carbonaceous dusts, Coke ash, Graphite dust, Alumina (Al2O3), Lime, Coal dust |
| In-house component manufacturing, pre-assembly of subassemblies, corrosion protection, commissioningAssembly | – | – | – | – | – |
| Welding fabrication (certificate DIN EN ISO 3834, factory production control according toJoining | – | – | – | – | Steel, Stainless steel, Aluminium |
| Design and construction of biogas plants / biochemical process engineering including fermenterEngineering | – | – | – | – | – |
| FOS/TAC automatic analyzer – automatic online measurement with integrated sampling and sampleTesting | – | – | – | – | – |
| Fermentation and digestion tests at laboratory and pilot-plant scaleTesting | – | – | – | – | Mineral substrates, Native organic substrates |
| Mechanical process engineering: shredding, crushing, grinding, sieve and air classification,Engineering | – | – | – | – | Mineral materials, Organic materials, Residual materials, Wastes |
| Thermal treatment in rotary kiln and sinter panHeat treatment | – | – | – | – | Industrial waste, Municipal waste, Raw and residual materials |
| Thermal treatment and melting in high-temperature chamber furnaces (also with shielding gasHeat treatment | – | – | – | – | Mineral melts |
| Microwave-assisted processesHeat treatment | – | – | – | – | – |
| Gravimetric dosing and dense-phase conveying of filter dusts with natural gas as carrier mediumEngineering | – | – | – | 250 kg/h – 500 kg/h | Filter dusts |
| Plastic injection (EKOFOR)Engineering | – | – | – | – | Plastic granulate |
| Pulverized coal injection (PCI+®)Engineering | – | – | – | – | Coal dust |
| Flue gas cleaning (ESCHSORB) / dry flue gas cleaningEngineering | – | – | – | – | Adsorbents, Activated carbon |
| Dosing of mold powder granulate (MULTIFLUX)Engineering | – | – | – | – | Mold powder granulate |
| Filter and homogenization floors (e.g. silo discharge fluidization floor DN 4200)Engineering | – | – | – | – | Coal dusts, Alumina granulate |
| Process development and control, complex automation (PLC control, PIMOS database)Engineering | – | – | – | – | – |
| Injectors with pneumatic dosing (multi-injector, e.g. quadruple with individual line control,Engineering | – | – | – | – | Coal dust, Coke dust, Petroleum coke, Sand, Lime, Iron ore, Granulated coal |
| Manufacture of ceramic membranes and systems, 3D-printed ceramic membranesPlastics | – | – | – | – | Ceramics |
| Gas analysis, digestate investigations, substrate characterizationTesting | – | – | – | – | – |
7 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Pilot rotary kiln | – | – | – | – | Unterwellenborn (pilot plant) |
| High-temperature chamber furnace (also with shielding gas purging) | – | – | – | – | Unterwellenborn (pilot plant) |
| Sinter pan | – | – | – | – | Unterwellenborn (pilot plant) |
| Biogas pilot plant (storage tank, fermenter, measurement station, PLC-controlled, PIMOS database) | – | – | – | – | Unterwellenborn (pilot plant) |
| Test rig for gasification of solid fuels | – | – | – | – | Unterwellenborn (pilot plant) |
| Test rig for pneumatic dense-phase conveying with natural gas and nitrogen control lines | – | – | 250–500 kg/h | – | Unterwellenborn (pilot plant) |
| Mobile test rig for injecting copper chips and granulate | – | – | – | – | Unterwellenborn (pilot plant) |
Additional services
Reference customers
Quality and certificates
E.S.C.H. GmbH is certified to DIN EN ISO 9001 and meets welding quality requirements in accordance with DIN EN ISO 3834 as well as factory production control according to EN 1090. In addition, the company is certified as a WHG specialist company (Federal Water Act) and under AMS – occupational safety with system.
| Evidence | Unterwellenborn |
|---|---|
| ISO 9001 | |
| EN 1090 | |
| ISO 3834 | |
| AMS – occupational safety with system | |
| WHG specialist company |
History
- 1979
Decisive impulses for pulverized coal injection from the research department of Maxhütte Unterwellenborn
- 1983
Commissioning of the first pulverized coal injection plant using the KOSTE process at blast furnace II of Maxhütte Unterwellenborn (February)
- 1985
Commissioning of the second pulverized coal injection plant (April)
- 1992
Founding of E.S.C.H. GmbH from the research department of Maxhütte Unterwellenborn