What is being built?

The cooling tower of MOL in Tiszaújváros is built using special construction methods

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A special feature of the project is a pool with a storage capacity of almost 2,500 cubic metres of water, which will provide firefighters with fire-fighting water in the event of a disaster. 

A cooling tower is added to the MOL Petrolkémia Zrt. site in Tiszaújváros. The large-capacity facility will be used to cool the industrial water used in the production of propylene, which is thus heated.

The construction work required for the implementation of the „Propylene Plant (Olefin Conversion Technology (OCU)) Project, Cooling Tower and Fire Water Supply” is being carried out by the North-East Hungarian Regional Directorate of MVM EGI Zrt. on behalf of SWIETELSKY Magyarország Kft. North-East Hungary Regional Directorate. During construction, special attention is paid to compliance with occupational safety requirements, as the work is carried out alongside operating plants.

Photos by Tamás Dernovics/magyarepitok.hu

In addition to the cooling tower, the project will also include the construction of ancillary facilities: a chemical dosing plant, a partial flow filter, a fire water powerhouse and five shaft structures. SWIETELSKY will complete the project this year in accordance with the contract schedule, after which the customer will carry out the process installation and trial runs, followed by commissioning early next year.

The project began in November 2022 with the preparatory, engineering and earthworks necessary for its implementation, and a year later the construction of the structure could begin, Peter Markó, project manager, informed our newspaper.

As he explained, the facilities are located on a 9,000 square metre site. The main element is the cooling tower, which is intended to cool the industrial water used in the production of plastics, which is heated up, and then reintroduce it back into the plant after purification. The tower has a storage capacity of around 2,500 cubic metres of clean water, which will also provide fire-fighting water for the plant fire brigade in the event of an emergency.

215 tonnes of reinforcing steel were used for the huge reinforced concrete structure

The details and parameters of the cooling tower were described by Mihály Balog, foreman: the structure has a floor area of 700 square metres and is 15 metres high, resting on a 160 cubic metre reinforced concrete slab foundation. Its superstructure is also reinforced concrete, covered by a 700 square metre slab, also of reinforced concrete. Inside the structure, a prefabricated beam grid is supported on two levels, which holds the various mechanical elements.

The main building is connected to three annexes and five smaller shafts, which house the technological equipment and mechanical units of the cooling tower.

"For the construction of the completed facility, we used about 2,000 cubic metres of concrete, 215 tonnes of reinforcing steel, which required the construction of about 7,000 square metres of formwork" - explained the foreman.

The works were carried out using a special solution

"During the construction, we used suspended scaffolding, which was suspended from precast concrete structures. The wall formwork, ironwork and concreting were also carried out from this work platform, so the structure did not have to be scaffolded all around, but the work was carried out from work platforms fixed to the wall section at the given height"

- said Mihály Balog. He added: "To formwork and support the slab, it was necessary to create a complete working level - under the slab - starting from the prefabricated beam level, the cantilevered parts of which - at the wall connection - were also solved with sleeves embedded in the wall and braces suspended on them. This was necessary because, as required by the customer, the mechanical installations during the formwork phase of the slab are carried out in parallel with the construction of the working level and the slab formwork."

The pool has passed the water-holding test

He cited the challenge of the cooling tower basin as the only way to retain the nearly 2,500 cubic metres of water is through the use of a watertight reinforced concrete slab and walls, so the proper placement and curing of the concrete is key to the building's success. The connection of the reinforced concrete structures of the pool area was ensured by the installation of watertight auxiliary waterproofing elements. As a result, the water-holding test was successfully carried out, a process that Mihály Balog considers to be one of the unique features of the project.

"The so-called water table test, which lasts several days, is part of the technical inspection of the pool area, during which the experts look for visible moisture on the walls below ground level. The special suspended work platforms on the walls above were also necessary because of tight deadlines, construction work was ongoing during the trial and because a 2.5 m deep and 2 m wide working pit had to be left next to the structure."

Particular safety rules must be observed

SWIETELSKY Magyarország Kft. pays particular attention to the highest standards of health and safety on all its projects, but within the scope of MOL Petrolkémia, they must also follow additional requirements regulated by the MCC SFBC requirements. "These regulations are important because we carry out construction work next to operating plants. Therefore, during construction, we had to implement all the safety precautions that are not or rarely required during general construction. Our company worked as closely and efficiently as possible with the investor's experts to comply with the general and the safety regulations of the MPK SFBC, thanks to which there were no safety accidents or related incidents during the construction work" - detailed project manager Péter Markó.

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