A Plant in Transition – on Its Way to the Future

The Campdorà Waste-to-Energy (WtE) Plant in Girona underwent a comprehensive modernization to comply with current European environmental and efficiency requirements while securing its long-term operational performance. The project combined the replacement of key plant components with the integration of new equipment into existing structures under demanding conditions. Fichtner RESA supported the implementation as technical advisor and was responsible for coordinating design, procurement, and construction through to commissioning.

From Legacy Plant to Future-Proof Waste-to-Energy Facility

When the City Council of Girona approved the project for the adaptation and energy efficiency improvement of the Campdorà WtE Plant in December 2015, the objective was clear: the existing plant was to be adapted to new European and national requirements, its lifetime extended, and its performance sustainably improved.

For the operator Trargisa, this meant a comprehensive modernization with continuous alignment to evolving regulatory requirements. In addition to complying with European directives, the focus was particularly on restoring and further developing the plant’s original performance capacity.

A Plant with a History – and a Significant Need for Modernization

Since its commissioning in 1984, the plant has played an important role in municipal waste treatment, processing an average of around 37,000 tons of waste per year. However, with aging infrastructure and increasing requirements regarding emissions and energy efficiency, it became clear that a fundamental upgrade was necessary.

From the outset, the project therefore followed an integrated approach: existing structures were to be utilized wherever possible, while key plant components were to be brought up to the latest technological standards.

From Initial Measures to Project Realignment

The implementation was originally planned in two phases. While initial priority measures were carried out in 2016 and 2017, it soon became apparent that the required adaptations were more extensive than initially envisaged.

The decision to temporarily shut down the plant at the end of 2017 therefore marked a significant turning point. It made it possible to fundamentally review the project and adapt it to the new circumstances.

A key factor in this process was the publication of the European Best Available Techniques (BAT) Conclusions for waste incineration in 2019. These introduced stricter requirements for emissions and plant operation and necessitated a partial redefinition of the technical solutions.

Involvement of Fichtner RESA and Redesign of the Project

Against this background, Fichtner RESA was contracted at the end of 2019 to provide technical assistance in further implementation of the project. Our scope included support in procurement procedures, technical and organizational coordination, as well as supervision of construction and commissioning.

During the review process, it became evident that key components of the plant had to be redesigned. In particular, what had initially been planned as an adaptation in the area of incineration evolved into a fundamental technological upgrade.

A key element of the redesign was replacing the two original 3 t/h furnaces and the common boiler with a single new furnace-boiler line that has equivalent thermal and mechanical capacity and a modern water-steam cycle.

Brownfield Construction as a Key Challenge

A defining feature of the project was the integration of new, high-performance technology into an existing plant structure.

The main challenge lay in the structural implementation: new components had to be integrated into an existing layout that had not been designed to accommodate them. This required tailor-made solutions – both in terms of civil engineering and in the arrangement of plant equipment.

At the same time, existing structures had to be reused wherever practical in order to minimize interventions and improve cost efficiency.

Technical Integration and Plant Upgrade

In addition to the new incineration unit, the energy generation system was also modernized and expanded in terms of capacity. Existing buildings were partially reused and selectively upgraded for this purpose.

Another focus was the assessment and adaptation of existing systems, particularly the flue gas cleaning system and plant control system. The aim was to retain existing equipment wherever feasible while bringing the overall plant to a consistent and modern standard.

Coordination of a Complex Overall Project

The modernization was divided into several individual project lots, each covering different technical areas. This resulted in a large number of interfaces that had to be coordinated throughout the entire project lifecycle.

Fichtner RESA took on the central role in coordinating planning, procurement, construction, and commissioning. In addition to technical coordination, this also included organizing construction activities and ensuring occupational health & safety.

Further challenges arose from external factors such as the COVID-19 pandemic and significant increases in raw material prices. These conditions required continuous adaptation of project management.

Implementation and Commissioning

Following completion of construction and installation works in spring 2025, a major milestone was achieved in June 2025: the first waste firing of the plant.

Since then, the project has entered the hot commissioning phase. During this stage, all systems are tested and optimized under real operating conditions before the contractually guaranteed performance parameters are finally verified.

Results and Outlook

The modernization has laid the foundation for reliable and efficient long-term operation of the plant. It will be capable of treating higher volumes of waste reaching up to 47,000 tons of waste per year and producing up to 3.4 MWe of electricity (almost twice the original setup), while meeting current environmental and emission standards.

The project demonstrates how existing infrastructure can be successfully upgraded through a targeted combination of technological renewal and integrated planning.

Conclusion

The modernization of the Campdorà Waste-to-Energy Plant shows that complex brownfield projects go far beyond purely technical upgrades. Success depends on forward-looking planning, close coordination among all stakeholders, and the ability to respond flexibly to changing conditions.

For Fichtner RESA, the project is another example of how demanding infrastructure projects can be successfully delivered in close collaboration with the client.

July 2026