Project Overview
Customer: Ingredion (formerly Corn Products)
Location: Stockton, California
Application: Cogeneration / Heat Recovery Steam Generator (HRSG)
Equipment:
- Selective Catalytic Reduction (SCR) system
- Haldor Topsøe catalyst
- Aqueous ammonia injection system
- Allen-Bradley PLC-based touchscreen controls
- SCR reactor housing and injection hardware
Ingredion’s Stockton processing facility operates a gas turbine and cogeneration Heat Recovery Steam Generator (HRSG) that recaptures turbine exhaust to generate energy for the plant. The facility needed a new SCR system capable of reducing NOx emissions to below 9 ppm while integrating with the existing HRSG.
The Challenge
Retrofitting emissions-control equipment into an existing HRSG presented several engineering and installation challenges.
The first step was obtaining accurate documentation, specifications, and field measurements of the existing equipment so the SCR system could be properly designed for safe and efficient operation.
Installation also required portions of the existing HRSG structure and internal components to be carefully disassembled. Multiple crew members and a crane were needed to lift components from the housing without damaging the equipment or surrounding steel structure.
The new SCR equipment then had to be integrated with the existing components and installed within the HRSG’s existing footprint.
The Solution
The complete SCR solution was engineered and integrated into the existing cogeneration HRSG.
The system incorporated a Haldor Topsøe catalyst along with Allen-Bradley PLC-based touchscreen controls specifically designed for SCR applications. The project also included the SCR reactor housing, injection hardware, construction support and commissioning services.
An aqueous ammonia system was selected for the reagent delivery system. The ammonia is stored in a water solution and vaporized into its gaseous state when required by the SCR process.
Because the SCR equipment needed to fit within the existing metal framework, cranes were used to lower the equipment into position from the top of the structure. The photos show how this installation is made possible.
The Results
The new SCR system exceeded Ingredion’s original emissions target.
Results at a Glance
- Achieved 5 ppm NOx emissions
- Exceeded the original target of below 9 ppm NOx
- Successfully passed the required source test
- Integrated SCR technology into the existing HRSG
- Completed installation in 48 hours
- Beat the planned 72-hour turnaround
- Minimized gas turbine downtiime and disruption to plant operations
Following minor instrumentation adjustments during commissioning, Ingredion successfully passed its source test. The SCR system achieved NOx emissions of 5 ppm—well below the facility’s original 9 ppm target.
The project also had an aggressive installation schedule designed to minimize turbine downtime. Although the team had committed to completing the work within 72 hours, installation was completed in just 48 hours.
Engineered SCR Solutions for Existing Equipment
Reducing NOx doesn’t always require replacing existing combustion equipment. Properly engineered SCR systems can be integrated into existing HRSGs and other industrial exhaust applications to achieve signifiant emissions reductions while working within existing plant constraints.
EcoCAT provides engineered SCR solutions including system design, catalyst integration, reagent delivery, controls, commissioning and emissions-performance support.
Need to reduce NOx emissions from an existing HRSG or industrial process? Contact EcoCAT to discuss an SCR solution engineered for your application.
Contact our emissions specialists to discuss your SCR application.