EcoCAT™ Selective Catalytic Reduction System

Location:

Atwater, California

Customer:

Teasdale Quality Foods, Inc.

Application:

Following a change in ownership, Teasdale Quality Foods aimed to upgrade its boiler system to comply with both current and future air quality regulations.

Key Challenges:

Founded in the 1930s, Teasdale Quality Foods has been providing high-quality products for over 70 years. Based in California, they are a recognized leader in supplying retail, food service, and industrial customers with a full line of hominy and dry soak beans. Over time, their steam plant deteriorated, leading to inefficiencies. They were operating the entire facility on a single boiler without an economizer, resulting in an inefficient production process and high air consumption.

Solution:

Teasdale Quality Foods initially contacted R.F. MacDonald Co. for a quote on a used boiler but soon realized that building an entirely new steam plant would be more cost-effective in the long run. R.F. MacDonald Co. provided comprehensive design and integration services for an SCR-based system. This included selecting the optimal site for the new foundation, installing the equipment, and providing training, all the way through completing the PG&E rebate process. Since they were constructing a new steam plant, Teasdale Quality Foods decided to upgrade all their equipment to state-of-the-art technology, ensuring compliance with both current and future air quality and performance standards.

The installation included:

• A Cleaver-Brooks Nebraska D-Type watertube boiler with all-membrane wall construction, designed for maximum efficiency and excellent NOx performance at 70,000 lbs/hr. The boiler was paired with a Cleaver-Brooks NATCOM low-NOx burner system, designed for 30 ppm NOx with FGR.
• R.F. MacDonald Co.’s in-house team fully designed and integrated Allen-Bradley PLC-based controls, and an economizer manufactured by e-Tech to meet the San Joaquin Air District’s Best Performance Standards.
• The system included an Industrial Steam DA system with feedwater pumps and an SCR system using a Haldor Topsøe Catalyst, achieving an exit NOx of 5 ppm with ammonia slip not exceeding 10 ppm.

R.F. MacDonald Co. handled every aspect of the project, from collaborating with architectural engineers to navigating air district regulations and securing PG&E rebates, treating every new account as an opportunity to build a strong partnership.

“Whether it’s working with your architectural engineer, dealing with the air district, or helping you handle your PG&E rebate, R.F. Macdonald Co. treats every new account as an opportunity to become a partner with the customer.”

R.F. MacDonald Co. guided Teasdale Quality Foods through the complex upgrade process from start to finish. They managed everything from specifying new equipment and top-level engineering to mechanical and electrical installation, including fuel and steam piping.

The new steam plant has been operational for several months with no issues, allowing Teasdale Quality Foods to complete the sale of their business successfully. R.F. MacDonald Co. continues to provide ongoing maintenance and support for the new owners, who are pleased with their modern, low-emission, and high-efficiency steam plant.