Location:
Stockton, California
Customer:
Ingredion
Application:
Ingredion, a global leader in ingredient solutions, processes raw materials like corn, tapioca, and wheat into various ingredients for the food, beverage, brewing, and pharmaceutical industries. Their Stockton plant operates a gas turbine with a cogen Heat Recovery Steam Generator (HRSG), which recaptures exhaust to generate electricity. Ingredion needed a new SCR system to reduce NOx emissions from this process to below 9 ppm. Having worked with R.F. MacDonald Co. on NOx-related issues in the past, they turned to them again for this project.
Key Challenges:
R.F. MacDonald Co. faced several challenges integrating the SCR system with the existing HRSG. The first step was obtaining accurate documentation and measurements of the existing equipment to design a compatible system. Next, the HRSG structure had to be disassembled, with components carefully removed using a crane to avoid damage. Finally, the new SCR system was installed and integrated into the HRSG housing.
Solution:
As a complete system integrator, R.F. MacDonald Co. provided equipment at every phase of the installation. The Haldor Topsøe catalyst SCR system was controlled by custom-designed Allen-Bradley PLC-based touchscreen controls. R.F. MacDonald Co. also supplied the SCR reactor housing, injection hardware, and handled construction and commissioning. To reduce site hazards, an aqueous ammonia system was recommended, which stores ammonia in water and vaporizes it for use in the SCR system.
Results:
The commissioning process went smoothly, with only minor instrumentation adjustments needed. The new SCR system achieved NOx emission levels of 5 ppm, well below the 9 ppm target. Additionally, the project was completed in just 48 hours, despite a 72-hour turnaround commitment, minimizing turbine downtime and maintaining plant operations. The success of this multi-phased project highlights the value of R.F. MacDonald Co.’s strong team of sub-vendors and in-house expertise.
