Client: BP Chemicals
Location: Port Lavaca, TX, U.S.
Business Segment: Energy Solutions
Industry: Chemicals
Executive Summary
Fluor was awarded the engineering, procurement and construction for the Green Lake project, which added an acrylonitrile reactor train and associated plant modifications to 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 would increase plant capacity by 33% to one billion pounds per year.
Fluor's Solution
We 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 ½ feet in diameter.
To improve schedule, we recommended erecting the surrounding steel structure prior to the reactor arrival. Then the reactor, which was 73 feet high and weighed 311 tons, would be lowered through the structure. This was the first time BP Chemicals had set an acrylonitrile reactor after structure erection.
Conclusion
With an aggressive schedule, the Green Lake plant achieved start up three months early in December 1996. Upon completion, BP Chemicals realized a significant added value and competitive advantage in the chemicals marketplace.
After completion of this project, we provided an ongoing maintenance presence at Green Lake.
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