Design and Build Van Phong 1 Environmental Compliance Chimney

Van Phong 1 Environmental Compliance Chimney

Case Study

Design and Build Van Phong 1 Environmental Compliance Chimney

The Van Phong 1 Thermal Power Plant in Vietnam features a landmark achievement in vertical construction: a 240-meter-tall emissions control structure, one of the tallest in Southeast Asia. This towering structure is critical to the plant’s environmental compliance, supporting advanced emission control systems, including electrostatic precipitators, flue gas desulfurisation, and low NOx burners, for the 1,320 MW super-critical coal-fired power plant.

To realise this ambitious design, the main contractor, Doosan Heavy Industries & Construction, required a specialised vertical construction expert capable of overcoming the unique engineering and logistical challenges posed by such a monumental structure. Balanced Engineering & Construction (BEC) was selected as the trusted partner due to its extensive experience and innovative methodologies in vertical infrastructure.

Project Challenges

The construction of the 240-meter-tall chimney presented several unique challenges. The project was executed during the COVID-19 pandemic, requiring strict adherence to local health protocols and innovative approaches to maintain timelines amidst global disruptions. The site, located on reclaimed land, posed significant geotechnical challenges, demanding advanced engineering techniques to ensure stability and safety. Additionally, working at extreme heights required meticulous planning, specialised equipment, and rigorous safety measures to protect workers and maintain precision during construction.

BEC's approach

Our approach combined advanced technology, skilled craftsmanship, and a fully integrated project scope of work that spanned the erection of slip forms, heavy lifting of structural components, and integration of internal rack-and-pinion hoists, aircraft warning lights (AWLs), internal lighting, lightning conductors, and earthing systems, as well as borosilicate linings and painting.

Specialised Slipform Erection: By utilising our advanced slipform erection technique, BEC facilitated continuous pouring, ensuring uniformity in material properties. This approach minimises the risk of structural weaknesses and enhances the chimney’s lifespan, particularly in demanding environments.
Advanced Heavy Lifting Capabilities: Our strand jack technology enabled the installation of the twin internal steel flues and roof and floor components. This cutting-edge lifting system allowed for the precise and safe handling of heavy loads at significant heights, ensuring efficiency and accuracy.
Integrated Multiskilled Team: BEC’s highly versatile team managed the entire scope, from slipform construction on reclaimed land to the application of borosilicate linings and finishing touches, such as painting. This end-to-end capability streamlined the process and ensured consistent quality control across all phases of the project.

By leveraging our unique methodologies and experienced team, BEC delivered a state-of-the-art chimney that is a testament to our expertise in large-scale vertical construction.

The BEC Advantage

Despite significant logistical and environmental challenges, BEC successfully delivered the world-class 240-meter-tall chimney on schedule, meeting stringent safety, durability, and operational standards. Our team achieved an impeccable safety record, completing 425,000 man-hours with zero accidents, incidents, or near misses, underscoring our unwavering commitment to a safe working environment. Innovative engineering solutions ensured stability on reclaimed land while rigorous safety protocols minimised risks during high-altitude operations. The application of borosilicate linings provided long-term durability and protection for the flues. Beyond its towering height, the chimney is critical in supporting advanced emissions control systems, helping minimise environmental impact and contribute to a more sustainable energy future. The Van Phong 1 project underscores BEC’s expertise in executing complex infrastructure projects with precision, reliability, and environmental stewardship.