Project manager Tor Gautestad gives updates on the progress.
Here is an update on the establishing of the world's first full-scale CO2-capture plant in the cement industry at Norcem Brevik. In short, the project is progressing roughly as planned, but with some additional challenges that are directly related to the war in Ukraine and the sanctions against Russia that have created global disruptions in the supply chain of materials and components.
Our challenges relate mainly to the delivery of stainless-steel pipes. The new facility requires lots of them, and it is still uncertain when the full amount will be delivered and available for prefabrication.
The activity on the construction site is steadily picking up, and our neighbours and passers-by are now observing major weekly changes, or actually daily. But despite a high level of activity, we are still happy to be able to report very good results on Health, Safety and Environment at the construction site, and there have been no serious incidents of any kind. The atmosphere is good, the commitment is great at all levels in the project, and the plant’s employees are eagerly watching the extreme transformation the plant is going through.
The project's largest contract on the construction side was awarded earlier this year to HAB, with head office at Lysaker. HAB started its work early June, and is now in the process of completing the foundations and concrete structures in the area where the capturing facility itself will be located (the process area). This part should be finished in early January when the plant's annual winter maintenance starts, and at the same time installation of the first process equipment in this area is initialized.
Staying in the process area, this is probably where we will experience the most excitement throughout 2023: Shortly after Easter, the big "Heavy-lift campaign" starts with the lifting of the huge process equipment in this area during only approximately 4 weeks. A giant crane with a lifting capacity of 650 tons then comes in, and will lift a number of components and modules weighing between 80 and 350 tons. The modules are now under construction at Trosvik in Brevik where components, pipes, pumps, valves, electrical installations and insulation are completed in large steel frames to be transported to the new Cementine-kaia at Norcem with barges and then lifted onto the area.
Already in the middle of January, the kiln stops for the annual winter maintenance of the, which this time starts two months earlier than usual and will last two weeks longer because of the CCS-project. In addition to the normal scope of maintenance of the cement plant, this time the project will replace the second of the two main fans (HV1) with a much larger unit, and we will replace the entire gas conditioning tower No.2 (GCT2). Both replacements are essential due to the much higher temperature these must operate under with the CCS-plant in operation.
All nine steam boilers are now in place, which will ensure heat recovery from the kiln’s exhaust gases. Throughout the winter, these will be equipped with platforms, pipes, valves etc.
In addition, the foundations for the large CO2-tanks behind the limestone storage on the jetty are under construction, and piling was completed a couple of months ago. Within short, the foundation will be cast, and in January the tanks will arrive and be put aside until the lifting period in April – May 2023.
2023 will be the major construction year, during which the major parts of the new facility will be put in place. All installation procedures are thoroughly planned, and we are confident that this will run smoothly and safe. Not because it will be easy, but because we have an incredibly strong and competent project organization that works hard and well together, and solves all small and large challenges every single day.