Energy & Chemical

Eichleay completed this $750 million grassroots environmental compliance project to enable the client to comply with an EPA consent decree.

The primary objectives of the overall effort were to reduce particulate, NOx, and SOx emissions. Major elements of scope included two Foster Wheeler high-pressure CO furnaces (the largest of the kind in the world) to heat crude more efficiently and produce steam without consuming fuel, two KTI SCR units, a Rentech waste heat boiler, and state of the art environmental technology consisting of a Belco pre-scrubber unit and a Cansolv absorber tower. The project also contained extensive earthwork, soil nail and tieback anchor retaining walls, electrical infrastructure upgrades, as well as utility upgrades and distribution. During the course of its three-year duration, construction manpower peaked at over 1,500 personnel.

$750m

grassroots environmental compliance project

Key Features:

Fast-track construction to meet an EPA deadline
Footprint of the units necessitated creating a new plot of land by cutting a new plateau from what was previously a hillside
Shutdown planning for tie-in to refinery
Fully integrated 3D modeling of entire facility

Installation of new furnaces in restricted access space with clearances of less than a foot between existing furnaces and pipe racks
Sequenced installation of structural steel and large diameter ductwork
Modularization of pipe rack offsite to reduce onsite manpower needs
Maximized use of offsite fabrication of piping and warehousing

Management of offsite lay-down yards due to lack of space in refinery
Complex crane management due to lack of available space and multiple work fronts
Emphasis on logistics planning for delivery of large equipment to worksite