Aurubis AG based in Hamburg (previously: Norddeutsche Affinerie) is one of Europe’s biggest copper producers and the world’s biggest copper recycler. The Group produces approximately 1.2 million tons of copper products every year. With some 4,700 employees, the company is also an international leader in the industry.
High quality requirements and international presence mean that Aurubis must not only carry out regular production controls, it also has to check the measurement consoles it uses here. During the course of this quality assurance it was found that the existing measurement consoles were not “state-of-the-art”, and they were subsequently modernized in the power plant and the Rohhütte Werk Nord (RWN) electric furnace.
The Dacobas product series provided by Knürr Technical Furniture, a leading specialist in ergonomics and technically sophisticated control console furniture, was brought into play with this project.
“From our point of view Dacobas and its special technical features meet all our requirements in matters ergonomics, flexibility and system modularity,” says Kai Schildt, Division Engineer for maintenance in the electrical, measuring and control technology areas at Rohhütte Werk Ost (RWO) in explaining his choice of supplier. He also managed the Power Plant Control Console project.

Functional workstations optimize control processes
Two measurement consoles were modernized at the Hamburg site, beginning with the one in the Aurubis power plant. A lot of the controlling used to be performed decentralized here, but with the implementation of the new control consoles, workers can now access and intervene from a central point. Division Engineer Kai Schildt’s top priority is that the new equipment complies with the respective standards and legalities, and that it be individually extendable.
The functionality of the measurement consoles is of fundamental importance for the entire plant, because all processes in the production of copper cathodes from copper concentrates and the further processing of copper wire, for example, can be controlled and delegated from here. As the individual production areas blend and correspond with one another, possible faults must be responded to quickly and flexibly.
The employee in charge of the control station in the power plant, who monitors and controls the respective parts of the plant on some 14 screens, is therefore bound to his workstation.
With regard to the first, already implemented system, not only has it been very well received by the workforce - the company is now also very conscious of the increasing importance of an optimally harmonized workstation, because ergonomic, tire-free working makes a critical contribution to successful production and a high level of quality.
The positive progression of the first project and the high-grade, functional systems also caused those in charge to bring in Knürr Technical Furniture’s experts again with the subsequent restructuring measures of the RWN E-furnace control station. “A control station must meet various criteria,” says Mr. Schildt. “On the one hand it is important that it be expandable; the workstation must be set up transparently, and it must provide the employee with plenty of comfort and ergonomics. And then it is also important that the solution be easy to maintain, and that we are not constantly under pressure to modernize.”

Individual solutions versus standard
“We also included other companies in the final selection, but we didn’t want any old standard technical furniture; we wanted individually-adjustable high quality furniture,” emphasizes Kai Schildt. When asked how his company found Knürr Technical Furniture, he answers that the supplier of their approx. 20 year-old equipment referred to Knürr’s services and portfolio. In addition to the individual scalability and modular setup, the company’s employees in particular like the color design and the appealing overall look of their new workstations. “Needless to say of course it is important that our colleagues fell good and actually like to work in the control stations,” adds Mr. Schildt. “This is why so much importance was placed on dynamic working with sit-stand workstations. The implementation of an additional standing console provides variation, so that our employees are not stuck in the same position all day long.”
The ideal use of space and rooms was achieved with the help of Knürr Technical Furniture’s qualified workstation experts, who carried out a current analysis on-site and drew up proposals for effective implementation. The Dacobas workstation systems and their well thought through setup, with its ergonomic legroom, for example, ensure freedom of movement for chairs in the link-up area of the module elements, as well as a more comfortable and more effective work environment.

Optimum workflow - thanks to the Dacobas Control Station
“With regard to the coordination of critical process flows, measurement consoles play a key role in the corporate structure. Competent advice and professional concepts are therefore critical criteria in this respect,” says Mr. Schildt.
While ergonomics are important for the operator, simple and fast access is important for the technician, so that the applications required for the operation can be implemented as quickly as possible. The components of the Dacobas series, which characterizes a clear modularly set up structure and the efficiency of control system-user interfaces, are especially well suited for these requirements.
In addition to individually adjusted viewing distances and viewing heights, various, depth-extendable worktops also provide additional flexibility.
The patented Dacobas quick-connecter system guarantees simple and strong workstation, cabinet and corner element linking. An easy to mount cable duct also enables hidden, vertical routing of all data and power supply cables. Threads in the top end of the extrusion allow adapters to be mounted for practical accessories. Additional work and storage surfaces are also provided with workstation components, with which a simple plug/screw connection is sufficient for linking up.
CRT monitors and TFT flat screens can be set up on the lowered monitor level and the high and tilt of the monitors can be set individually with inlay plates.
In combination with technical pedestals and mobile drawer units, the workstation systems provide the ideal equipment for 24-hour constant operation measurement consoles.

Control console representative function
Another important aspect is the console’s representative function, because it is often displayed to the interested public during plant tours. A holistic and appealing design is an obligation for Aurubis’ appearance, and not a freestyle event.
Mr. Schildt draws a positive conclusion at the end of the day: “I really have to say how uncomplicated and direct the cooperation and coordination was during the project. Our requests were very readily received and incorporated into the implementation. Additional components were also ordered later on without difficulty and quickly delivered.”