Dillinger

Acoustic detail planning for a direct reduction plant

View of the construction site (source: SHS – Stahl-Holding-Saar)

As part of the future-oriented Power4Steel project, Dillinger is planning to build a direct reduction plant (DRI) and electric arc furnaces (EAF) to replace blast furnaces. The goal is to transform steel production towards low CO₂ emissions. Müller-BBM Industry Solutions is supporting this pioneering project with comprehensive acoustic engineering expertise to ensure approval compliance and quality.

At a glance

Client:Aktien-Gesellschaft der Dillinger Hüttenwerke,
SHS - Stahl-Holding-Saar
Branche:Steel industry
Object:Direct reduction plant
Expertise:Noise control, occupational safety
Location:Dillingen, Saarland

Initial situation

Dillinger operates modern facilities for pig iron and steel production as well as high-performance rolling mills at its Dillingen site. As part of a comprehensive site transformation, the parent company SHS – Stahl-Holding-Saar Group is focusing on forward-looking technologies: plans include a direct reduction plant in Dillingen and electric arc furnaces in Dillingen and Völklingen.

The new DRI plant is based on the innovative Midrex Flex technology, which enables flexible use of natural gas and hydrogen in varying mixing ratios. With an annual production capacity of around 2 million tons of directly reduced iron, it makes a decisive contribution to decarbonizing steel production.

The goal of the project is to reduce CO₂ emissions by up to 55%, equivalent to an annual saving of around 4.8 million tons of CO₂ – a milestone for the sustainable transformation of the European steel industry.

Mission

Müller-BBM Industry Solutions prepares the TA Lärm noise prediction for the entire plant and defines acoustic requirements for all sub-sections.

Noise and emission control
  • Design of noise mitigation measures
  • Preparation of noise emission forecast in accordance with TA Lärm
  • Definition of acoustic requirements for:
    • Facades, roof structures
    • Ventilation elements
    • Machine enclosures
  • Construction supervision for quality assurance starting in 2026
  • Consulting on approval processes and emission quotas
Immission control
  • Indicative immission forecast according to TA Luft
  • Measurement planning based on a proTerra assessment to determine suitable measurement locations
  • Approval of the measurement plan by authorities
  • 12‑month measurements at three monitoring points
Occupational safety

In parallel, Dillinger places special emphasis on occupational safety. Therefore, Müller-BBM also provides advice and support in this area, for example:

  • Defining requirements for control rooms and operator cabins
  • Fundamentals for the acoustic design of crane cabins
  • Assessment of interior noise levels in process control

Chronology

2022

Immission measurements from June 2022 to June 2023 at three monitoring points.

2023

Project start with comprehensive consulting as part of land-use planning

2024

Start of construction for the DRI plant and electric arc furnace in Dillingen

2026

Construction site inspections for quality-assurance checks of acoustic measures by MBBM Industry Solutions

2028/29

Planned commissioning of the direct reduction plant as well as one electric arc furnace each in Dillingen and Völklingen

Model of the EAF in Dillingen (source: SHS – Stahl-Holding-Saar)

Challenges

From an acoustic perspective, this project is exceptionally demanding. To ensure approval compliance, noise mitigation measures must be implemented that in some cases go well beyond the usual state of the art.

This applies both to the design of plant equipment and to the structural execution of the new buildings. Thanks to close collaboration with Dillinger, these requirements can be systematically and purposefully implemented.

Müller-BBM Industry Solutions is delighted to contribute its expertise to one of the largest transformation projects in the European steel industry.

3D model of the direct reduction plant (source: SHS – Stahl-Holding-Saar)
3D model of the electric arc furnace (source: SHS – Stahl-Holding-Saar)

Learn more about our areas of expertise

[Translate to English:] Arbeitssicherheit, Arbeitsschutzmanagementsystem

Occupational safety

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[Translate to English:] Gewerbeimmobilien, Industrie, Lärmschutz

Noise protection

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