Project Highlights

Client

Flying J Inc.

Location

North Salt Lake, Utah

Mission

Replace inefficient TCC unit with MSCC and TSS units; meet EPA new source emissions rules

Goals

  • Increase capacity
  • Reduce emissions
  • Better use of available crude mix

Major Players

  • UOP LLC – process technology licensor
  • IAG – project management

Project Cost

$33 million

Results

  • 25-month return on investment
  • Completed on budget
  • Lower ongoing operating costs
  • Increased production
  • Expansion of refinery crude slate

To use its available crude mix more efficiently at its refinery in North Salt Lake, Utah, Flying J built a grassroots MSCC unit – the first of its kind in the U.S. – and used a Third Stage Separator (TSS) in a unique application to meet EPA New Source Performance Standards.

Following an initial feasibility study, IAG provided detailed cost estimates and overall project management, working with Flying J and UOP over the course of two years. Several obstacles needed to be addressed after completion of the initial scope, including an increase in capital investment and limited plot space for the installation of a new stub tower and an ESP downstream of the MSCC regenerator.

To help solve both issues, Flying J chose a UOP TSS for the removal of particulate matter from the MSCC flue gas. This strictly environmental application was a departure from the traditional role of the TSS as protection for a power recovery expander. With MSCC performance rated “very satisfactory” by the client, the TSS succeeded in producing fewer particulate emissions than the EPA required.

The close cooperation between Flying J, UOP and IAG contributed to a cost-effective project with a simple payout of 25 months.