AKW Equipment + Process Design applies wet mechanical expertise to OTTO DÖRNER Group’s ORCA project
1 The project by the OTTO DÖRNER Group contributes to Germany’s ambition to build an efficient circular economy. Each year, approximately 220 mill. t of construction waste are produced nationwide
© AKW Equipment + Process Design
Since 2022, AKW Equipment + Process Design has been comprehensively supporting the project, leveraging its holistic range of services – from concept development and engineering through to the construction and commissioning of turnkey. The scale of the undertaking sets economic benchmarks as well: with an investment volume of € 22 mill., the project represents the largest single investment in OTTO DÖRNER Group’s history. Supported by € 2.7 mill. from the Federal Ministry for the Environment’s Environmental Innovation Program, the ORCA plant was conceived as a reference example for sustainable construction material utilization in Europe. The commissioning phase has already started and is set to be completed by September 2025.
Focus on fine-grained fractions
AKW Equipment + Process Design’s objective was to deliver an economically and ecologically optimized solution that achieves two main goals:
the processing of mineral-based materials into standardized recycled aggregate fractions
the production of a pollutant-free, high-quality 0 – 2 mm recycled sand fraction suitable for use in the concrete industry
2 The AKW plant for the ORCA project under assembly in Seevetal, near Hamburg/Germany
© AKW Equipment + Process Design
The technical concept – modular and high-performance
The processing line developed for ORCA achieves a total capacity of up to 150 t/h (0 – 32 mm), with throughputs of 50 – 100 t/h for the fine-grain fraction (0 – 2 mm). Key components include:
AKA-TRIT high performance attrition cells for targeted surface cleaning and activation of sand grains, including bypass and half-load functions
AKA-SORTER upstream sorter for efficient density separation and removal of light organic contaminants
AKOREL free-fall classifier for precise creation of customer-specific target gradations
AKA-VORTEX hydrocyclones for desludging and removal of ultra-fine particles
Additional water treatment systems including clarifiers and chamber filter presses
The overall system enables a flexible, high-performance, and resource-efficient production of up to four marketable fractions:
63 µm – 2 mm
2 – 8 mm
8 – 16 mm
16 – 32 mm
The residues (< 63 µm) mainly consist of organic components and mineral sludges.
A contribution to the Substitute Building Materials Ordinance (EBV)
The ORCA facility represents a forward-looking response to the requirements of the Substitute Building Materials Ordinance (EBV), in effect since 1 August 2023. This ordinance sets uniform national standards for recycled construction materials, aiming to strengthen confidence in their environmental safety and technical suitability. The technologies used ensure compliant material quality through precise, multi-stage separation and cleaning processes.
A strong signal for sustainable construction
“The ORCA project marks a major milestone in the transition toward a more sustainable construction industry,” says Thibaut Richard, Managing Director of AKW Equipment + Process Design. “It demonstrates how waste can become a valuable raw material – and how advanced technology can make a functioning circular economy a reality.”
