The inaugural large-scale Carbon Capture Utilization (CCU) plant has been established for the German cement industry with Engineering from Mammoet.

3D engineering facilitates efficient and safe operations within confined spaces.

Mammoet is actively contributing to the decarbonization of the industry by delivering safe and efficient solutions for the transportation and installation of heavy objects. This commitment was exemplified during the construction of the first large-scale Carbon Capture and Utilization (CCU) plant at the Lengfurt site of Heidelberg Materials, a leading global manufacturer of building materials.

Leveraging its extensive engineering expertise and years of experience, Mammoet was engaged by Linde Engineering to devise a comprehensive lifting and installation strategy for a range of large components.

Engaging early in the process promotes effective planning.

The confined space and the involvement of multiple contractors necessitated meticulous planning of workflows, interfaces, and construction timelines. A comprehensive feasibility study was conducted a year prior to the execution phase, during which various solution options were thoroughly analyzed and evaluated.

Utilizing a 3D model of the existing cement plant, Mammoet's team effectively employed its proprietary engineering platform, Move3D, to visualize the intricate processes, spatial requirements, and potential conflicts within the confined construction site. This visualization enhanced the understanding of the planned operations for all stakeholders and facilitated improved coordination.

The implementation of a 750-ton crawler crane emerged as the most adaptable and efficient solution for the safe and timely lifting and installation of large components within the constrained construction environment. With the aid of three-dimensional planning, the crawler track for the crane was minimized, thereby reducing the impact of lifting operations.

Mammoet's strategy encompassed the delivery of large components to the construction site, the planning of pre-dressing areas within the swing radius of the crawler crane, and the setup of the crane for heavy lifts.

By engaging early in the process, Mammoet's team was able to offer invaluable recommendations for modifying the layout of the CCU plant to meet installation requirements. Furthermore, the spatial considerations were integrated into the overall construction site logistics, resulting in a safe, efficient, and seamless execution that ultimately saved the customer both time and costs.

Ensure secure installations with a versatile crawler crane solution.

Initially, the 100-ton absorber column was erected in the pre-dressing area utilizing a tandem lift technique. The load was maneuvered nearly 180 degrees on the crawler crane's hook and transported approximately 20 meters to its designated installation position. At this location, the column required meticulous guidance behind a building before it could be accurately positioned, aligned, and secured to the foundation within the steel structure.

Given the absorber column's 55-meter length and the intricate nature of the lifting operation, this represented the most formidable heavy lift encountered during the project.

Subsequently, the installation process included the 67-ton stripper column, four tanks each weighing 72 tons, and ultimately, the 178-ton heat exchanger.

Mammoet's crawler crane solution provided several essential benefits. The crane's flexibility enabled it to safely lift loads of various sizes and weights over extended distances, thereby eliminating the need for intermediate transport on site. To facilitate pre-installation and concurrent construction of the steel structure, the crawler crane's configuration was modified shortly before the project's commencement, resulting in significant time savings.

The early engagement of Mammoet, combined with 3D engineering, diligent oversight by planning engineers on-site, and a collaborative approach characterized by openness, solution orientation, and trust, played a pivotal role in the project's success.

About Cap2U

Heidelberg Materials and Linde have launched a joint venture named 'Capture-to-Use' (Cap2U) to construct and operate a carbon dioxide capture and liquefaction facility. This facility is currently under construction at the Lengfurt cement plant site, with planning and construction being managed by Linde Engineering.

More information on Cap2U