Projects

Graycor Industrial completed a fast-track rebuild of Blast Furnace "C" at Severstal′s Dearborn, MI, plant. This complex design-build challenge required six months of preplanning to develop a unique and innovative approach to complete the construction phase within the scheduled 100-day outage.

The project also included construction and installation of a casthouse weighing approximately 1,500 t…

In partnership with Sargent & Lundy, 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 …

This project required coal-handling and crusher-house modifications and upgrades. The project scope included installing a new radial stacker and conveyor gallery and expanding the transfer house. Our team also modified the head and tail pulley system to increase the speed of all major conveyor sections. Graycor assisted in the planning, scheduling and budget development.

Our involvement exten…

Graycor Industrial Constructors Inc. is nearing completion of construction of a new hydrogen plant for Praxair at its Whiting, Ind. facility. The multimillion-dollar project will enable Praxair to supply hydrogen to BP's Whiting, Ind. refinery. BP, one of the world's largest oil and gas firms, will use the hydrogen in production of ultra-low-sulfur gasoline and diesel fuels. The new plant will s…

A flue gas desulfurization (FGD) project was recently completed for American Electric Power Service Corporation (AEP) in Brilliant, Ohio. Construction of the 18-month project consisted of retrofitting AEP's 630-megawatt Unit 3 with equipment to reduce sulfur dioxide (SO2) emissions. More than 1,700 tons of structural steel was used to construct six structures. Well before the project began, Gra…

Pittsburgh-based Calgon Carbon Corporation, a global leader in services and solutions for making water and air safer and cleaner, called upon Graycor Industrial Constructors Inc. to expand the company's manufacturing capabilities at their Catlettsburg, Ky. facility. The project included new structural steel and mechanical installations of a grinding mill, as well as associated equipment and pip…

This design-build project at the power producer's Marseilles, Illinois, location included construction of the office and service buildings inside of the protected area. Scope of work involved installation of five 115-ton rooftop air conditioning units as part of the mechanical equipment package. The Graycor Industrial team also enclosed the railroad track way, constructed a high-bay mechanical m…

This design-build project included construction of a two-story administration building, as well as a three-story high-bay building inside of Dresden's protected area. Project scope also included a two-story interconnecting walkway, locker rooms, cafeteria and mechanical shops. In addition, a halon fire-protected records vault was installed. The project team also completed final tie-ins to the ex…

Graycor Industrial replaced two 40,000-lb./hr heating boilers inside the Dresden Station protected area. Scope of work for this project also included all boiler and related equipment installation, a new stack, and auxiliary work. All work performed for this project required "hot area" precautions.

This project included excavation, removal and replacement of existing 12-inch fire main encircling the turbine building inside of the protected area. Before beginning the project, the Graycor Industrial team probed for locating existing underground utilities. Fine excavation was completed using high-volume vacuum trucks.

Graycor Industrial completed the construction of a dry cask storage system at Point Beach Nuclear Plant in Two Rivers, Wisconsin. Scope of work included construction of eight new ventilated concrete storage casks (each 11 foot by 18 foot), two large VCC and ISFSI storage pads, perimeter security fencing and a pre-engineered building with foundations. In addition, the Graycor Industrial team comp…

Graycor Industrial completed construction of this world-scale manufacturing plant to produce soybean-based polyols for Minneapolis-based Cargill, a food and agriculture products company. The new $22-million BiOH™ brand polyols manufacturing plant in Chicago is the first world-scale biobased polyols plant. The new plant will produce Cargill's BiOH™ soybean-based polyols using a proprietary new g…

This project, conducted at the Allen S. King plant, included a selective catalytic reduction (SCR) retrofit and an air quality control systems (AQCS) installation, which required two scheduled outages. The first consisted of removing ductwork and associated steel, and installing new structural steel and transition ductwork. The second outage included final tie-ins and installation of the catalys…

How do you replace an entire building without interrupting the day-to-day operations inside? With a 24,000-square-foot roof in dire need of replacement and a building in poor condition, Stepan Company brought Graycor Industrial on as general contractor to help answer that question. The first step was to erect a new, pre-engineered building around the existing one. Stepan Company is a global manu…

This multi-phased project included installation of concrete foundations, structural steel, pre-cast, masonry, siding and roofing to enclose the new production line within a three-story building. Installation of the production line itself called for extensive carbon and stainless piping expertise, electrical work (including explosion-proof instrumentation) and equipment setting of mixers, agitato…

Graycor performed critical excavation and foundation work for the $365 million natural gas liquids processing and production facility. The project was completed within Aux Sable′s aggressive six-month timeframe.

This project involved full-scope, heavy-duty process work, including: demolition and replacement of foundations and entry/exit terminal equipment (including accumulators), removal and replacement of existing strip furnace refractory and all associated piping and electrical work. Large piping components were prefabricated prior to installation and structural steel was assembled on the ground as m…

Graycor Industrial was  contracted to construct an enclosed 138kv-13.8V substation - housing for an  electrical transmission and distribution center - in downtown Louisville.

Building  the new substation called for demolition of the previous facility, located on  the future site of a multi-purpose arena. The project included site work, CIP  concrete structure, PVC roo…

Graycor Industrial constructed a 300-megawatt peaker  plant for University Park Energy, LLC. The facility produces electricity for  sale on the wholesale market during periods of peak demand. We furnished labor,  materials, equipment and supervision to erect six Pratt and Whitney twin-pack  combustion turbines. Additionally, Graycor performed all excavation, concrete,  p…

The Southeast Chicago Energy Project was a joint effort by Exelon Generation and Peoples Energy′s (PERC) Power Generation team, a direct subsidiary of Peoples Energy, that develops, owns and operates power generation facilities.

The Chicago Energy Project was constructed on a site about 10 miles from downtown Chicago and now adds power generation capacity to the city of Chicago, while helping…

As part of Bighorn Constructors, Graycor Industrial completed engineering, procurement and construction (EPC) work on  Reliant Energy′s 548-megawatt combined-cycle power plant to serve the  surrounding region. The project involved installation of two combustion  turbines, one steam turbine, two heat-recovery steam generators, an air-cooled  condenser and a switchyard.

Bigh…

Reliant Energy contracted GSSL joint venture - between  Graycor, Sachs Electric Co. and Sargent & Lundy LLC - for the design-build  construction of an 870-megawatt, simple-cycle peaker plant in Aurora, IL. Work  included installation of 10 combustion turbines, erection and implementation of  a control building, installation of massive raw water and denim tanks, site …

This joint venture was managed by Graycor Industrial and completed construction of a simple-cycle peaker plant in University Park, IL. The facility generates 530- megawatts of  supplemental electrical power during Chicago′s peak power periods.

The project  included installation of 12 natural gas-fired combustion turbine generators, as  well as civil construction. Houston-b…

Graycor Industrial was contracted by EPC Siemens Westinghouse to construct a 300-megawatt, natural gas-fired peaker power-generation facility for the Calumet Energy Project in Chicago. Hired as the general contractor, Graycor handled all site and  construction work, design of various project components, and purchase of select  construction equipment. Calumet  E…

Graycor Industrial performed coal-handling modifications and upgrades for long- time client Midwest Generation at its Fisk Station, including the installation of a 45-degree-angle conveyor and reversal  of the five major conveyor sections. Our team assisted in the planning, schedule and budget development, and was responsible for project management and all constructability is…

Graycor Industrial completed a two-phased project for Lafarge North America′s cement distribution facility in Detroit. Phase one included construction of a new silo - Lafarge′s largest in North America - including installing the facility′s foundations, slip-forming the 106-foot-diameter by 183-foot-high storage silo and placing the silo roof and two interior elevated floors.

Compared to most …

The Allen S. King Plant′s Metropolitan Emissions Project included a selective catalytic reduction (SCR) retrofit and air quality control system (AQCS) installation. Two outages were scheduled. The first consisted of removing ductwork and associated steel, and installing new structural steel and transition ductwork. The second outage included final tie-ins and installation of the catalyst. The to…

Graycor was contracted to construct NIPSCO′s largest SCR/air heater unit to date. Work included demolition of the existing tubular air heater, erection of structural steel, fabrication and installation of four distinct duct systems, an Alstom Lungstom Air Pre-Heater, an SCR and associated civil and architectural equipment.

Associated Electric Cooperative, Inc. awarded Graycor Industrial an environmental controls retrofit project near Clifton Hill, located in northern Missouri. The fast-track project consisted of installing two air heaters and two selective catalytic reduction (SCR) units, demolishing and rebuilding an existing electrostatic precipitator, and performing associated ductwork, structural steel and ins…

City Water, Light & Power (CWLP), the largest municipal utility in Illinois and sole supplier of electricity for the state capitol of Springfield, contracted Graycor to install the first three selective catalytic reducers (SCRs) at its Dallman power station. The SCRs were designed to reduce nitrogen oxide emissions from the facility′s three existing coal-fired, steam-turbine units. Work incl…

This two-phased project involved installing flue-gas desulfurization (FGD) and selective catalytic reduction (SCR) systems to reduce sulfur dioxide and nitrogen oxide emissions from the plant′s Unit No. 4. Phase one of the project consisted of substructure work, including foundations, underground utilities, roadways, site grading and surfacing. Phase two involved all superstructures supporting t…

Graycor Industrial recently completed an environmental retrofit project at Ameren's Duck Creek power station, a 440-megawatt, coal-fired generation facility, located in Canton, Ill. The fast-track, design-build 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…

Graycor Industrial served as construction contractor for Lurgi Lentjes of North America on its new SCR installation. In addition to renovation and modification of the existing facility, the project required demolition of existing air heaters and ductwork. Work also involved an eight-week tie-in outage of ductwork and new operating systems, including the ammonia system.

The first phase of this multi-phased project included furnishing and installing a new pipe bridge from the baghouse to the basic oxygen furnace building. Then our team installed a fume collection system, including the baghouse, dust silo, duct and roof canopy. Graycor crews were also responsible for the baghouse′s piling and foundations, in addition to structural, electrical, piping, siding, lea…

This project was performed for Mountain State Carbon, a joint venture between Wheeling-Pittsburgh Steel and Severstal, NA. Graycor Industrial′s scope of work for the project included complete through-wall repairs for 39 oven walls and end-flue repairs for the remaining walls. Structural and collecting-main upgrades, installation of gas collection piping, and replacement of coke side and pusher s…

Overall, this project for Ispat Inland (now ArcelorMittal) called for implementing a bottom tap and demolishing the furnace base and lining. It also required installing a new hearth bottom and walls, tuyere, bosh refractory and staves in the bosh and stack. In addition, we removed and replaced the lip ring, and demolished and installed the stove dome, hot blast main, bustle pipe lining and stove…

Graycor has provided construction services for ArcelorMittal (ISG at the time of the project) since 1982. More recently, we completed repairs designed to improve the quality of air emitted from the steel producer′s Indiana Harbor Works BOF (Basic Oxygen Furnace).

The project called for replacing chamber Nos. 3 and 4 collection plates and discharge electrodes on the BOF precipitator as well as…

Beta Steel Corp. called upon Graycor Industrial Constructors to handle multiple system upgrades at their Portage, IN, plant. Graycor performed coiler-handling system improvements, including the installation of a new downcoiler, two new walking beams, an inspection station and a pre-engineered metal building. In addition, the project entailed sheet piling, foundation demolition, new foundation in…

A year-long installation at the Burns Harbor plant was performed at the No. 1 Basic Oxygen Furnace (BOF). Graycor's work included erecting a baghouse and installing all associated ductwork and support steel, reinforcing the existing building, and relocating existing piping and electrical interferences.

The project required two 1,000-ton cranes to move extremely large ducts and install them in…