The new heat recovery steam generators installed by Sarens are industrial equipment that harnesses waste heat from energy processes to produce steam and improve the plant's energy efficiency.
Indorama Eleme Fertilizer & Chemicals Limited plant specializes in the manufacture and distribution of nitrogen fertilizers used in agriculture to improve crop growth and yield.
Sarens deployed the Demag CC2000 crawler crane, which has a 330-ton lifting capacity and a maximum main boom length of 276 fee to perform the major lifts thanks to its high load capacity and stability.
Sarens, world leader in heavy lifting, engineered transport, and its division in Nigeria, Sarens Buildwell, carried out a complex heavy transport and lifting operation on behalf of its client IPI (Iron Product Industries) in the Indorama Fertilizer Plant located in Port Harcourt, Nigeria. The task undertaken consisted in the installation of two HRSG (Heat Recovery Steam Generator) modules, identified as PG-A and PG-B, which weighed 152 and 120 tons respectively and measured 42 meters high by 15 meters long. The new heat recovery steam generators installed by Sarens are industrial equipment that harnesses waste heat from energy processes to produce steam and improve the plant's energy efficiency.
Prior to the project, during the planning phase, Sarens' engineering team conducted an in-depth preliminary study that analyzed the routes between the port and the plant in detail, assessing potential logistical and operational risks. One of the main challenges faced was the condition of the site's terrain, which required leveling and compaction work. To ensure the stability of the lifting equipment, steel plates were laid before installing the crane support mats. In addition, the manufacturer provided technical drawings for several of the oversized cargo (ODC) packages.
After assessing the site and terrain conditions, Sarens' team selected a combination of lifting and heavy transport equipment adapted to the dimensions and weights of the loads to ensure the successful execution of the operations. Among these, the main piece of equipment deployed was the Demag CC2000 crawler crane, which has a 330-ton lifting capacity and a maximum main boom length of 276 feet. Its function was to perform the major lifts thanks to its high load capacity and stability in heavy industrial work.
A Liebherr LTM1300-1 mobile crane was also used as support. This all-terrain telescopic crane has great maneuverability, which allowed it to perform auxiliary and assistance tasks during assembly and lifting operations. HMT (Hydraulic Modular Trailers) with 12 axle lines were used to transport the components. This type of trailer allows the configuration of transport platforms adapted to oversized loads, such as the generators.
The modules were transported from the port to the plant site by road, taking approximately half a day, with two additional rotational trips to complete the project logistics. The CC2000 crane took four days to assemble, while the LTM1300-1 was operational after only four hours of setup. In total, the cranes remained at the work site for six days. The HRSG modules, which weighed 152 and 120 tons respectively and measured 42 meters high by 15 meters long, were lifted using crawl mode, with the crane moving slowly on its tracks. The project involved a team of crane operators, lifting supervisors, site engineers, and health and safety (HSE) specialists.
The Indorama Eleme Fertilizer & Chemicals Limited plant specializes in the manufacture and distribution of nitrogen fertilizers used in agriculture to improve crop growth and yield. Its main product is granulated urea, one of the most widely used fertilizers in the world due to its high nitrogen content, essential for plants such as corn, rice and wheat. In addition to urea, the plant also produces ammonia.
Mohammed Kamal, Project Manager and PHC Depot Manager at Sarens Buildwell, commented: “The Indorama project demonstrates Sarens’ ability to plan and execute complex heavy transport and lifting operations in demanding industrial environments, even in difficult terrain conditions and with the added complication of heavy rainfall. Thanks to our technical expertise, we have been able to contribute to the expansion of the plant, which will have a positive impact on the region, boosting the local economy and creating new employment opportunities."
For its operations in Nigeria, where it landed in 2011, Sarens has formed a strategic partnership with Buildwell, a Nigerian transport, logistics, and heavy equipment services company that has been operating since 1977. Together, they have created the Sarens Buildwell Joint Venture, through which they operate on various projects in both the oil and gas sector and other industries such as construction.
About Sarens
Sarens is the global leader and reference in crane rental, heavy lift and engineered transportation services. With state-of-the-art equipment, value engineering, one of the world's largest inventories of cranes, transporters and special rigging equipment, Sarens offers creative and intelligent solutions to today's heavy lifting and engineering transport challenges.
With more than 100 entities in 65 countries operating without borders, Sarens is an ideal partner for small to large-scale projects. Sarens currently employs 6,000 highly qualified professionals who are ready to serve the needs of any client worldwide and in all market sectors. https://www.sarens.com/