Vital Energi RDF Upgrade – Port Clarence

Engineering a New Future for Existing Infrastructure

At Port Clarence in County Durham, Vital Energi faced a significant engineering challenge. The plant was originally built and just before it was finally commissioned the project was abandoned. Vital then bought the plant and decided to Hire Turmec to upgrade the plant to RDF

The existing biomass fuel handling system had reached the point where a transition to Refuse Derived Fuel (RDF) was required. The change was far more complex than replacing conveyors—it required reimagining how fuel would be received, transported and delivered to the incinerator while working within an operational energy-from-waste facility.

Rather than designing around a blank canvas, Turmec was tasked with designing around an existing one.

The challenge demanded structural steel that could integrate seamlessly with existing infrastructure while providing the flexibility, durability and reliability required for decades of continuous operation.

Turning Constraints into Opportunity

Every aspect of the project was developed to maximise performance while minimising disruption to the operating plant.

The existing biomass handling equipment—including hoppers, augers, conveyors, structural steel and access walkways—was carefully decommissioned and removed.

In its place, Turmec designed an entirely new fuel handling system centred around a bespoke structural steel lattice supporting a dual conveyor arrangement extending from the fuel reception area to the incinerator feed.

The structure was designed not only to carry the conveyor system safely but also to accommodate maintenance access, future servicing requirements and long-term operational resilience.

Every steel component was fabricated to EN1090 standards and hot-dip galvanised to EN ISO 1461, providing maximum durability in a challenging industrial environment.

Structural Steel Designed Around Reliability

Unlike conventional conveyor installations, the structural design had to support complete operational redundancy.

The lattice structure accommodates twin conveyor systems running the entire length of the installation.

Should one conveyor require maintenance, the second can immediately take over, allowing the facility to continue operating without interruption.

This approach significantly reduces operational risk while maximising plant availability.

The structure also supports:

• Fully enclosed conveyor corridors

• Maintenance walkways

• GRP flooring

• Integrated lighting

• Electrical containment

• Sensor systems

• Future maintenance access

Every element was considered during design to ensure operators could safely access equipment while maintaining continuous plant operation.

Innovation at the Heart of the Design

One of the project's most innovative engineering solutions is the quick-change shuttle conveyor at the grate feed.

Recognising that this location experiences the highest wear within the system, Turmec developed a rapid replacement design allowing the shuttle conveyor to be exchanged within hours rather than days.

The supporting structural steel was specifically engineered to facilitate this process, dramatically reducing future downtime and maintenance costs.

The grate feed itself has also been designed to maintain a consistent RDF plug, ensuring stable combustion performance and improved energy recovery

Engineering Beyond Conveyors

Structural steel forms the backbone of numerous integrated systems throughout the project.

The new installation supports:

• RDF reception walking floors

• Dual conveyor transport system

• Ash handling equipment

• Radial ash storage conveyor

• Odour control ducting

• MCC cable routes

• Access platforms

• Maintenance infrastructure

By integrating multiple disciplines into a single engineered structure, Turmec has created a highly efficient, future-ready installation that supports both current operations and future expansion.

Sustainability Through Engineering

Rather than replacing the entire facility, the project extends the life of an existing energy-from-waste plant through intelligent engineering.

The transition from biomass handling to RDF enables Vital Energi to process a wider range of waste-derived fuels while maximising energy recovery.

The new conveyor system has been designed to minimise material handling, reduce bottlenecks and improve process efficiency.

Automatic lubrication systems reduce maintenance requirements and extend equipment life, while enclosed conveyor corridors and a dedicated odour control system improve environmental performance for both operators and the surrounding community.

By upgrading existing infrastructure rather than rebuilding from scratch, the project significantly reduces embodied carbon associated with major construction while delivering a modern, high-performance solution.

Designed for the Entire Lifecycle

Turmec believes successful engineering extends well beyond project completion.

Every component within the installation is digitally supported through Turmec's QR-enabled aftersales platform, allowing operators to instantly access machine documentation, spare parts information and maintenance records.

The system is backed by Turmec's rapid response aftersales service, preventative maintenance programmes and tailored Service Level Agreements, ensuring the structural and mechanical assets continue to perform at their optimum throughout their operational life.

A Partnership in Engineering Excellence

The Port Clarence RDF Upgrade demonstrates how structural steel can be used not simply as a supporting framework, but as the foundation of an integrated engineering solution.

Working closely with Vital Energi and specialist project partners, Turmec has delivered a resilient, highly maintainable and future-proof installation that transforms an existing biomass facility into a modern RDF handling system.

The project showcases the role structural steel plays in enabling innovation, improving operational resilience and supporting the transition to more sustainable energy recovery infrastructure.

It is an example of engineering that not only solves today's operational challenges but is designed to meet tomorrow's demands.

Why this project stands out

• Transformative upgrade of a live energy-from-waste facility without complete reconstruction.

• Bespoke structural steel lattice engineered to support a fully redundant dual-conveyor system.

• Innovative quick-change conveyor design reducing maintenance downtime from days to hours.

• High-specification galvanised structural steel designed for long-term durability and minimal maintenance.

• Integrated multidisciplinary solution combining structural, mechanical, electrical and environmental engineering.

• Sustainable approach extending the operational life of existing infrastructure while supporting greater resource recovery and energy generation.