Extended Intervals, Maximum Service Life: The Evolution of the Explosion Power Service Concept

In the world of Energy from Waste (EfW) and power generation, every percentage point of availability counts. Maintenance shutdowns are necessary, but they must be planned intelligently. We have done our homework: based on field data (1 million shock pulses per year) and continuous endurance tests (300,000 shock pulses per year), we have innovated our service concept.

The heart of this optimisation is the significant extension of service intervals for a key component – the transfer block. This component is now replaced after 28,000 cycles instead of the previous 7,000 cycles.

In parallel, this technological reliability allows the maximum time interval for standard service to be extended from 18 to 30 months. These adjustments enable far more flexible outage planning and ensure that the service life of the components are fully utilised.

The evolution of the concept is not only evident inside the equipment but also in the logistics. Over a maintenance cycle of 28,000 cycles, both weight and volume have been drastically reduced:

• Weight savings of service kits: A fully equipped service kit is, on average, between 13 kg and 18 kg lighter. Over the entire cycle, this saves a total of 70 kg in material and transport weight for the SPGr10.
• Volume optimisation: The optimised packaging alone has reduced the volume by up to 46% (for the SPGr10, this corresponds to a saving of approx. 450 litres).
• Handling: More compact and lighter kits mean a noticeable simplification for the onsite team, while the proven protective function and stability of the packaging have been fully enhanced for the daily maintenance routine.

The improved environmental balance of the new concept follows a clear logic: by extending the service life of the transfer block, significantly fewer components need to be manufactured initially. This reduces both material consumption and the energy required for production directly at the source.

At the same time, the proven principle of refurbishment remains ecologically sound: other components continue to be refurbished, ensuring their useful life is fully maximised. The result is a service concept that combines economic benefits with a responsible use of resources.

Valuable optimisation potential has been unlocked through a broad database of practical field experience. We are passing this success directly on to plant operators. Through targeted process optimisation and drastically extended component service life, operating expenditure (OPEX) is significantly reduced. It is a classic win-win situation: higher technological efficiency leads directly to an improved economic balance over the entire lifecycle of the plant.

From 1 April 2026, this innovation will become the new standard. This optimisation demonstrates how practical expertise flows directly into relieving the burden on operational maintenance.

This evolution proves: those who know their data can push boundaries – for increased availability and an optimised environmental balance.