BP Chemicals
Port Lavaca, TX, U.S.

BP Chemicals Acrylonitrile Reactor Train

​Fluor was awarded the engineering, procurement and construction for the Green Lake project, which added an acrylonitrile reactor train and associated plant modifications at the BP Chemicals Green Lake plant.  

The project was fast-tracked to meet an aggressive 18-month total schedule. Upon completion of the expansion, Green Lake was the world's largest acrylonitrile production plant.

Client's Challenge

​Acrylonitrile is a clear liquid used in the manufacture of ABS plastic for end use in automotive parts, appliances, acrylic fibers like carpeting and clothing, nitrile rubber and a broad range of consumer products.

The Green Lake expansion comprised the addition of an acrylonitrile train, revamp of recovery and purification units, revamp of acetone cyanohydrin unit and replacement of fire damaged piping system associated with the 21 MW steam turbine/generator set.

The new unit increased plant capacity by 33 percent to one billion pounds per year.​​

Fluor's Solution

​Fluor provided engineering and procurement, as well as funding estimates, for each activity. The critical erection of the acrylonitrile reactor was successfully set one month ahead of schedule. The reactor was fabricated in northern Spain and weighed 385 tons, at 96 feet overall length and 24-1/2 feet in diameter.

To improve schedule, Fluor recommended erecting the surrounding steel structure prior to the reactor arrival and lower the reactor th​rough the structure, which was 73 feet high and weighed 311 tons. This was the first time BP Chemicals had set an acrylonitrile reactor after structure erection.


​With an aggressive schedule, the Green Lake plant achieved star up three months early in December 1996. Upon completion, BP Chemicals realized a significant added value and competitive advantage in the chemicals marketplace. Fluor maintains a continued presence at Green Lake with an ongoing maintenance presence.