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Transporting of a Large Plant

Logistical masterpiece

Transporting of a Large Plant

1 June 2024

Chief Technology Officer

When designing the systems, long before the first weld seam, we make sure that our machines fit into the so-called container dimensions. This is necessary because every mile on the road would cost 800,000 dollars and entire traffic light systems would have to be rebuilt.

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A pyrolysis plant goes on a journey. Sturdy packaging and a strong film cover protect the plant during the several weeks of transport by lorry and ship. The destination is Australia.

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A pyrolysis plant goes on a journey. Sturdy packaging and a strong film cover protect the plant during the several weeks of transport by lorry and ship. The destination is Australia.

Costly transport

When I plan a system, I know that it won't stay here in Tangstedt near Hamburg. Once it has been built in our hall, it has to reach its destination as efficiently as possible. Preparation for transport is time-consuming, even if a smaller plant is being built for us, i.e. for operation here in Germany. Our current pyrolysis plant has a throughput of 5 tonnes per day and weighs around 15 tonnes with all ancillary equipment.

The largest reactor we can build is 32 metres long and weighs 120 tonnes with everything included.

Large industrial plants

Industrial plants are a completely different kettle of fish. The largest thing we could build and transport today is a reactor with a throughput of 5.5 tonnes per hour. It is 32 metres long, has a diameter of 3.80 metres and weighs 120 tonnes with all the trimmings. This pushes us to the limits of what can be shipped.

Such a monster is even more difficult to transport by road. In the USA, for example, one mile would cost around 800,000 dollars, according to the specialist company that handles road transport for us. That's too much to make such transport worthwhile.

Because all our systems have to be transportable and easy to assemble, we set ourselves a limit: all parts of a system must be a maximum of 12 metres long, 2.30 metres wide and 2.40 metres high. This means that each part fits into a 40-foot container.

Fluctuating temperatures, salt water and high waves, we have to protect our high-tech system from all this so that it doesn't arrive with rust after 5 weeks.

Before and after transport by sea, the containers have to be transported by lorry. We therefore also have to take the weight distribution into account during planning and construction. Our systems must therefore not only function and achieve the required quality, but also fulfil the logistical constraints.

Together with my team in Hamburg, I also ensure that the parts of the system can be installed next to each other, connected and put into operation in Melbourne.

Transport by sea

Before the time comes and the journey to the USA or Australia can begin, we first wrap all parts of the system in film to protect them from moisture from the outside. On the inside, we use equalising filling material and desiccant to prevent condensation from forming under the film in the event of temperature fluctuations. We don't want the machines to start rusting and arrive at the port with damage after a few weeks.

Our job is only done when everything is up and running: the plant and the circular economy.

As the weather at sea can quickly change with high waves, we also protect the system from impacts. It's as if we were building a kind of garden shed around the parts of the system. Protruding parts must also be padded. Thanks to our planning process, the transport costs and transport emissions are ultimately comparable with all other products travelling the world's oceans.

On-site support

If you buy a system from us, we will not simply leave you on your own after installation. Part of our concept is to help establish a functioning circular economy at the production site. So our job is only done when everything is running smoothly. Because your success is our success.

In Australia, for example, we are currently doing this with the waste disposal specialist . After a test phase, operations got off to such a good start that we will soon be travelling to Australia again. This time with four 40-foot containers in our luggage.

Author

Ben Richters

Chief Technology Officer

After completing his technical training and gaining initial professional experience in the automotive sector, Ben Richters transitioned into mechanical engineering. As a graduate engineer, he shifted his focus to plant engineering, particularly in the field of petrochemical industry. In 2015, he became an entrepreneur in the green tech circular economy industry. He joined enespa in mid-2022 as the developer of the enespa pyrolysis plant prototype. Outside of work, he finds balance in timber construction. He loves spending time with his family at the harbour in Hamburg.

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