What is a flue pipe? Most people are familiar with it. But what on earth is a rotary kiln pipe? Simply put, it is the central component of a rotary kiln. This cylindrical furnace, which continuously rotates around its own axis during operation, is used, for example, in cement production. And that’s exactly what the rotary kiln that Schmidbauer deployed in March 2024 at Schwenk Zement in Mergelstetten near Heidenheim will do. However, its primary purpose is not cement production, but rather a higher goal.
This rotary kiln pipe is part of a research project on CO2 capture in cement production, initiated by the four cement manufacturers Dyckerhoff, Heidelberg Materials, SCHWENK Zement, and Vicat under the name “catch4climate.” Using an innovative process, the pilot plant aims to increase the already high CO2 emissions to about 90 percent of the generated exhaust gases and then capture them as comprehensively as possible. This captured CO2 can then be used to produce essential products like fertilizers, fuels, or plastics, which are currently made from fossil carbon sources, in a climate-neutral way. In this way, the CO2 generated during cement production does not go to waste in the atmosphere.
Before the 35-meter-long and approximately 115-ton rotary kiln pipe arrived at its destination, it had already traveled by river from Hamm-Uentrop to Heilbronn Harbor and then by heavy-duty transporter to Mergelstetten. Despite its massive size, it is considered relatively compact within the industry, making it the first of its kind to be transported and assembled in one piece, complete with its riding ring and girth gear.
Then came the moment: Enter Schmidbauer. With the precision of Mikado players, the heavy-lift experts hooked the long, steel behemoth to their Liebherr LTM 1650-8.1 rotary crane, which boasts a lifting capacity of 700 tons. Carefully, they lifted the load from the truck boom to a height of about 13 meters and executed a smooth 180-degree swivel. This allowed the rotary kiln pipe to hover precisely over the prepared kiln foundations, where it was placed with millimeter accuracy. Mission accomplished – with a single, uninterrupted lift.
The catch4climate research kiln is expected to go into operation in the first quarter of 2025, with the project itself set to run for three years. Schmidbauer’s involvement, however, was successfully completed in just about 30 minutes. Yet it was indispensable in advancing the energy transition within the vital construction sector, paving the way for a livable future for us all.
Check out the exciting video of the operation here: CI4C Ofeneinbau Mergelstetten (youtube.com)
Equipment:
- Liebherr Mobilkran LTM 1650 8.1
Location: SCHWENK Cement Plant Mergelstetten
Duration: March 7, 2024
