Archer Daniels Midland Company
ADM Columbus Carbon Capture Project
Project Highlights
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Performance Contractors constructed critical components of the ADM Columbus Carbon Capture Project, the world’s largest bioethanol carbon capture operation, within ADM’s continuously operating Corn Processing Complex in Columbus, Nebraska. The scope included carbon capture and compression facilities across two operating mills, with 295 tons of structural steel, 43 pieces of equipment, and 1,700 linear feet of process and utility piping. Performance completed the work without interrupting plant operations while supporting a system designed to route captured CO₂ to permanent underground storage.
Scope/Services
Equipment Assembly & Erection
Module Installation
Pipe Installation
Rigging & Heavy Lifts
Steel Fabrication
Structural Steel Erection
Industry
Renewable Fuels
Carbon Capture (CCUS)
Capability
Capital Construction
Module Assembly & Installation
Pipe & Steel Fabrication
Location
Columbus, NE
The Challenge
The project’s toughest challenge was executing substantial critical-path construction inside a continuously operating production complex. The carbon capture system had to be integrated into fermentation systems serving two separate mills without interrupting either operation, while limited laydown space, restricted crane positions, congested work areas, and narrow system-isolation windows placed significant constraints on construction.
Schedule pressure was compounded by long-lead rotating equipment and harsh Nebraska winter conditions, including extended sub-freezing temperatures, wind, and ice during periods when grouting, structural steel, and scheduled tie-ins were on the critical path. Large-bore stainless steel CO₂ piping also demanded exceptional quality because rework within the operating facility could have meant losing a limited execution window.
What We Did Differently
Performance separated the scope into outage-dependent activities and work that could be completed while the mills remained in full production, allowing the majority of construction to advance without disrupting operations. Installation Work Packages and Performance’s proprietary FLoW system were used to plan every component of the scope, with work packages continuously resequenced around changing material and equipment deliveries to keep crews productive. When weather affected the schedule, the team recovered through deliberate resequencing and targeted night shifts rather than simply increasing manpower.
The team also looked for ways to move difficult work out of the operating environment. Rather than erecting elevated pipe bridges piece by piece above live equipment, Performance assembled complete bridge sections at grade and installed them in single picks, reducing elevated work and exposure over operating systems. Detailed equipment-setting sequences, project-specific cleanliness controls, in-house welder qualification, and extensive lift planning further protected schedule and quality—contributing to a 0.0% weld reject rate and 0 recordables across 41,904 man-hours.
Project Total Quantities
- Structural Steel Installation { 295 Tons
- Equipment Set { 43 pieces
- Pipe Installation { 1,700 LF
- Modules Installed { 10
- Manhours { 37,562
- TRIR { 0.00
Item
Quantity
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