A Pioneering Green Hydrogen Plant in the Netherlands
Lagos — Shell’s Holland Hydrogen 1 is a groundbreaking project that marks Europe’s first large-scale green hydrogen plant. This renewable energy initiative features electrolyser units with a total capacity of 200MW, capable of producing up to 60,000kg of hydrogen per day. The facility draws power from the Hollandse Kust Noord offshore wind farm, making it a significant step towards sustainable energy solutions.
The project has wide-reaching implications for energy-intensive sectors such as construction and road haulage, where reliable and sustainable fuel sources are essential. To meet these ambitious goals, substantial engineering expertise was required to ensure the project could be completed on time and within specifications.
Mammoet played a crucial role in the project from its early stages, providing guidance on constructability during the FEED (Front End Engineering Design) phase. Their involvement extended to planning and managing the transportation and lifting operations necessary to bring the facility to life.
Challenges of Construction
The site, located behind the sand dunes of the Dutch coast, presented unique challenges. The surrounding area was in constant development, making access difficult. Additionally, the workspace itself was limited, with multiple contractors working simultaneously, further complicating the process.
Mammoet’s early engagement, meticulous planning, and precision engineering were vital in ensuring that the largest components of this pioneering project were delivered safely and on schedule.
Planning the Construction Process
For over two years, Mammoet supported Shell with constructability planning for the facility, contributing to the engineering design process. This experience, gained from decades of handling complex modular construction projects, helped Shell develop an optimal modularization strategy.
“We started our involvement by supporting the route survey as part of a broader pre-study,” said Paul van der Waal, Tender Specialist at Mammoet. “I was actively involved in constructability meetings to assess the build from a transport and lift perspective.”
From this study, the team identified the best routes and equipment needed to transport the heaviest items—many of which arrived by sea—to the site. The Euromax Terminal in Rotterdam was chosen as the receiving port.
A detailed study of a section of the quayside was conducted to ensure the ground could support the weight of the heaviest components, avoiding any limitations on module size and cost-efficiency.
Once unloaded using a 750t mobile crane, the heavy items were placed onto conventional trailers pulled by prime movers. They were either stored temporarily in the port or transported directly to the site, which was 15km away.
Ensuring Safe and Efficient Lifts and Transport
After the FEED phase, Mammoet took a leading role in the delivery process, providing the means to unload, transport, and prepare components for installation.
Emissions were strictly prohibited during critical phases of the project indoors. Mammoet, having previously worked to de-carbonize many heavy lifting and transport operations, was well-prepared for this scenario.
Zero-emission equipment was used on-site, including a heavy duty carrier (HDC hydraulic platform trailer), robot mover, and LTC1050-3.1E crane—all powered by electricity. Mammoet operators performed all lifts for items exceeding one tonne.
Mobile cranes with capacities ranging between 60 and 750 tonnes were used throughout the project. Heavy items were installed by being skidded or lifted into position. Transformers weighing 90-165t were installed using skidding and jacking techniques. Ten large air cooler units, each weighing 80t, were lifted onto the facility’s roof using a dedicated steel structure.
Mammoet also assisted in installing around 200 items inside the building housing the electrolyser. These included ten electrolyser units, each constructed from approximately 20 parts.
Collaborative Efforts and Modular Solutions
With limited space on the site, finding ways to reduce on-site disruption was a top priority. This led to the decision to fabricate a large pipe rack unit offsite rather than inside the facility.
Mammoet successfully moved and installed the rack in two sections, offering a modular construction solution that saved time, space, and minimized disruptions.
Early involvement and effective communication brought significant benefits to the project. Dedicated engineering and operations teams from Mammoet supported every stage of the process.
“We had an active on-site team fully immersed in the process,” said Marco Barendregt, Project Manager at Mammoet. “We maintained good communication with Shell and all other parties involved in the mechanical, steel, and construction aspects of the build. This ensured the installation schedule ran smoothly, with every heavy movement integrated seamlessly with the next.”
A Step Toward a Sustainable Future
This project exemplifies how long-term experience in modular construction is being leveraged to build future sustainable energy alternatives. Its successful completion represents another milestone in the journey toward an emission-free future for heavy industry, supported by emission-free equipment provided by Mammoet.
