Environmental
Building a better environment for the future.
As the demand increases for creating a cleaner environment, industrial owners across the U.S. continue to be challenged by impending deadlines to comply with environmental standards. At Graycor Industrial Constructors Inc., we make it our job to help our clients meet those deadlines and accomplish their goals by providing cutting-edge construction services. Whether it is a coal-fired power plant, steelmaking facility or processing center, Graycor Industrial is well-qualified and -equipped to execute and meet our clients' most demanding project goals and expectations.
Air quality control means cleaner air.
As a result of recent laws enacted within the U.S. governing emission standards among industrial plants, many owners - from steelmakers and power plants to manufacturing and processing facilities - are upgrading their equipment to reduce pollutants released into the atmosphere created by the burning fossil fuels. Standards generally regulate the emissions of nitrous oxide, sulfur dioxide, particulate matter or soot, carbon monoxide, volatile hydrocarbons, and mercury, among others.
Graycor Industrial provides environmental construction services within each of the markets in which we work - power, metals and process.
POWER
At Graycor Industrial, we bring our power clients a unique
combination of experience, expertise and resources-along with the
ability to manage the most sophisticated projects with maximum
efficiency, consistency and safety. Our expertise includes: balance
of plant, air quality and environmental, new generation, wind and
renewable energy, and transmission and distribution. The following
is a select list of our recently completed and/or ongoing
environmental power projects:
AmerenEnergy Resources Generating Co. (Ameren) - WFGD
Retrofit - Canton, Illinois
Ameren's Duck Creek power station, a 440-megawatt, coal-fired
generation facility, located in Canton, Ill., recently underwent an
environmental retrofit. The project included replacing an existing
FGD system with a wet flue gas desulfurization (WFGD) system. The
new scrubber system will more efficiently remove, or "scrub,"
sulfur dioxide from the flue gas emissions. The retrofit project
also included installation of an eight-cell, electrostatic
precipitator and associated foundations and equipment. In 2003,
Graycor Industrial installed a selective catalytic reduction (SCR)
system at the Duck Creek plant.
American Electric Power (AEP) - FGD Retrofit -
Brilliant, Ohio
Currently underway is a flue gas desulfurization (FGD) project
that Graycor Industrial is performing at AEP's Brilliant, Ohio,
plant. Construction of the 18-month project was substantially
completed by the end of 2009, with tie-in work currently scheduled
for 2011. The work consists of retrofitting AEP's 630-megawatt Unit
3 with equipment to reduce sulfur dioxide (SO2) emissions. More
than 1,700 tons of structural steel Is being used for construction
of six structures.
American Electric Power (AEP) - Environmental Retrofit -
Conesville, Ohio
Graycor Industrial recently completed an environmental retrofit
project at the power producer's 1,745-megawatt coal-fired
generation facility in Conesville, Ohio, located 70 miles east of
Columbus. The two-phased project included all substructures and
superstructures supporting the FGD that was installed. Work on the
780-megawatt Unit 4, the plant's largest unit, resulted in a
reduction of sulfur dioxide emissions. The substructures portion of
the project included a significant amount of site work and
underground utilities.
City Water, Light & Power (CWLP) - SCR Installation
- Springfield, Illinois
City Water, Light & Power (CWLP), the largest municipal
utility in the state of Illinois and sole supplier of electricity
for the city of Springfield, Ill., contracted Graycor Industrial to
install three selective catalytic reducers (SCRs) at the Dallman
Power Station in Springfield. The SCRs, the first to be installed
on the site, are designed to reduce nitrogen oxide emissions from
the facility's three existing coal-fired, steam-turbine units.
Graycor Industrial's work included installation of the SCRs,
retrofitting foundations and installation of structural steel and
ductwork to support the SCR installations.
Midwest Generation - ACI Projects - Various Illinois
Plants
In partnership with Sargent & Lundy LLC, Graycor Industrial
designed, furnished and installed Activated Carbon Injection (ACI)
systems for 12 boilers at six Midwest Generation plants throughout
central and northern Illinois. In ACI technology, powdered
activated carbon sorbent is injected into the flue gas duct where
the sorbent binds with the mercury in order to prevent the mercury
from being emitted into the atmosphere.
Xcel Energy - Metropolitan Emissions Reduction Project -
Oak Park Heights, Minnesota
Graycor Industrial completed a major rehabilitation of Xcel
Energy's 530-megawatt Allen S. King power plant in Oak Park
Heights, Minn. (near Minneapolis/St. Paul). The project involved
retrofitting the single-unit plant with pollution control equipment
and performing rehabilitation work that will keep the plant running
for an additional 30 years with greatly improved reliability. Major
components of the project consisted of an SCR (selective catalytic
reduction) retrofit and AQCS (air quality control system), or
scrubber, installation. The SCR retrofit also included major
ductwork and all associated structural support steel. In addition,
Graycor crews installed spray dryer absorbers, baghouses and all
associated ductwork required to tie the AQCS system into the SCR
and existing plant.
METALS
Graycor Industrial is a leading self-performing contractor serving
the steel industry. We're structured to deliver under many contract
arrangements-from performing part of a given job to helping you
tackle the entire project from conception to completion. We are one
of only a few North American contractors with a proven track record
in both coke battery and blast furnace work. With that kind of
expertise, Graycor Industrial is able to perform our clients' most
challenging environmental jobs, which include the following recent
work:
ArcelorMittal - BOF MACT Installation - Burns Harbor,
Indiana
Graycor Industrial recently completed work on an emissions control
system installation project for ArcelorMittal Steel USA at its
Burns Harbor steelmaking and processing facility in Indiana. The
project was completed to meet Maximum Achievable Control Technology
(MACT) Standards, which are technology-based air emission standards
established under Title III of the 1990 Clean Air Act Amendments.
Work on the two-phased, year-long project at the No. 1 Basic Oxygen
Furnace (BOF) consisted of erecting a baghouse and installing all
associated ductwork and support steel, reinforcing the existing
building, and relocating existing piping and electrical
interferences.
ArcelorMittal - BOF MACT Installation - East Chicago,
Indiana
Graycor Industrial completed another emissions control system
installation project for ArcelorMittal at its East Chicago, Ind.,
steelmaking and processing facility. The six-month project was also
completed to meet Maximum Achievable Control Technology (MACT)
Standards. Work at the East Chicago plant included installation of
the MACT scrubber system and all associated ductwork and support
steel for the No. 4 BOF.
Graycor Industrial has been working for ArcelorMittal (formerly Ispat Inland and Inland Steel Co. at the East Chicago site and Bethlehem Steel and International Steel Group at the Burns Harbor site) for nearly five decades.
PROCESS
Graycor Industrial's process group specializes in the construction
and renovation of complex systems and piping necessary for
processing oil, gas and chemicals. For decades, we've been building
long-lasting, mutually rewarding relationships with some of the
most sophisticated companies in the world-clients like Calgon,
Cargill, Citgo, Forbo, Marathon and Stepan Company.
Recently completed environmental projects in the process market
include the following:
Calgon Carbon Corporation - Plant Expansion -
Catlettsburg, Kentucky
Pittsburgh-based Calgon Carbon Corporation, a global leader in
services and solutions for making water and air safer and cleaner,
called upon Graycor Industrial to expand the company's
manufacturing capabilities at its Catlettsburg, Ky., facility. The
recently completed project included new structural steel and
mechanical installations of a grinding mill, as well as associated
equipment and piping installations. The equipment grinds granular
activated carbon (GAC) to a fine powdered activated carbon (FPAC)
in order to be used in activated carbon injection systems which
power producers use to reduce noxious Mercury emissions at power
generating stations.
Cargill - New Biobased Polyols Plant - Chicago,
Illinois
Graycor Industrial completed construction of the first world-scale
biobased polyols plant for Cargill in Chicago. In just nine
and a half months, Graycor constructed the entire plant from
foundations through electrical, controls and plant commissioning.
The new plant produces Cargill's BiOH™ soybean-based polyols using
a proprietary new green process. Cargill's BiOH ™polyols provide a
responsible choice in raw materials for furniture cushioning,
bedding foams, automotive seats and building insulation.
Environmental building team.
To ensure we are leading our clients in the right direction for their business, we have a team of seasoned professionals and self-perform capabilities. We also look to consistently educate our professionals in the methods, materials and technology needed to complete projects in the most timely and cost-effective manner possible. This includes the latest in building-information modeling, Web-based project management tools and other collaborative project management technologies that assist in delivering a top-notch heavy industrial environmental project.
Resource links.
Graycor Industrial Constructors Inc. is a member or and/or works closely with the following organizations to provide quality environmental construction services:
U.S. Department of Energy: http://www.energy.gov/
Professional Service Industries, Inc. (PSI): http://www.psiusa.com/
Graycor Blasting Company Inc.: http://graycor.com/markets/blasting
For more information, contact:
POWER
Tom Gore
Senior Vice President
630.684.7346
tom_gore@graycor.com
METALS
Ted Vrehas
Project Director
219.763.8771
ted_vrehas@graycor.com
PROCESS
Larry Dumford
Manager, Business Development
708.408.9251
larry_dumford@graycor.com
