Project: Modular Construction of a dual furnace for a Biofuel Factory

For a new biofuel factory, MOB has assembled two modular furnaces. Modular construction was completed at our yard within four months. 

The larger furnace was built using five modules, while the smaller one used three modules. By assembling the modules at a site near the final destination, MOB ensured a seamless and safe preparation for the eventual installation at the factory.

Modular Construction

Modular construction is a building method that continues to gain ground thanks to its numerous advantages. This method allows for parallel construction of modules at different construction sites and locations, better quality control at the module manufacturing site, reduced safety risks, and more control at the assembly site. And most importantly: it results in a shorter installation time at the factory.

For the purpose of constructing a new biofuel factory, MOB assembled two modular furnaces. The larger furnace was built using five modules, while the smaller one used three modules. By assembling the modules at a site near the final destination, MOB ensured a seamless and safe preparation for the eventual installation at the factory.

Thorough Preparation

As a first step, a comprehensive construction sequence plan was developed based on the 3D drawings and documentation. This plan outlined the construction sequence of the modules, including all pipes, valves, cage ladders, chimneys, platforms, and other components.

The large modules were delivered by ship from Romania. Weighing between 40 and 60 tons, these modules were transported from the dock to the construction site. All other components, such as pre-heaters, chimneys, and pipelines down to bolts and nuts, were delivered by around 40 large trucks. All parts were first set up and sorted, taking into account the construction sequence.

At the construction site, a base frame was carefully prepared on which the furnaces could be assembled. Consideration was also given to the SPMTs (Self-Propelled Modular Transporters) that would eventually transport the assembled furnaces back to the dock.
 
 
 
Construction phase As much assembly work as possible was performed on the ground. Multiple teams worked simultaneously on different modules. Walkways were installed around the modules on the ground, after which the modules, including the walkways, were lifted into place.

After the placement of each module, construction work, reinforcement, and attachment of support structures followed. Once in place, all modules and walkways were connected, and stairs and grates were installed.

The coils in the furnace posed a final challenge. The piping was already present in the modules, but these needed to be welded in a confined space to connect the pipes between the modules.

The furnaces were assembled over four months. The project proceeded safely and without incidents, within the specified timeframe.