A few of the many projects Lipten has completed.
Ground-up Construction of Two Sister Power Plants
Lipten was tasked with the design and build of energy plants for a pair of ethanol production facilities from the ground up. One facility is located in Indiana the other in Illinois with each producing up to 335,000 pounds of steam per hour. Auxiliary systems included R.O. water treatment, chilled water and compressed air. Lipten designed the plants and systems, supplied the equipment and managed all the installation and construction. As part of this effort, Lipten designed and furnished all of the boiler and balance of plant control systems.
Multiple Burner Replacements: 630,000 lb/hr steam system
Lipten converted two coal-fired boilers to fire natural gas at a vehicle assembly plant in Missouri. Because of the nature of the furnace configuration, vertical burners were chosen instead of horizontal burners. These burners provide optimum flame geometry for the specific furnace configuration, improved thermal efficiency, better overall boiler performance, avoidance of flame impingement and simplified operation. The project included new forced draft fans, natural gas supply systems, electrical modifications, and custom Programmable Logic Controller (PLC) control systems from Lipten’s Controls Division.
Increased Efficiency: 38MW Heat Exchanger System
Lipten designed and installed a massive condensing heat exchanger that required extensive modifications to the plant’s existing gas turbine system. Our thermodynamics engineers designed a system to best use waste heat to preheat process water. Our civil engineers designed the most cost effective solution to install the equipment and modify the turbine exhaust structure. This project was a great example on how Lipten has helped find unique solutions for customer needs.
Multiple Boiler Replacement with Detailed Civil Engineering
Industry: Food & Beverage
Lipten provided design-build services for the installation of two new 120,000 lb/hr packaged superheated steam boilers, low NOx burners, controls and ancillary systems. Lipten also provided integration into an existing 100+ year old building including elimination of the second floor, modifications of the building to support equipment, wall openings to facilitate equipment entry and new equipment foundations. Careful planning went into ensuring a smooth change-over to the new equipment with no loss in the facility’s product production.
New Controls allowing for plant wide system integration
Lipten’s Controls team assisted in a multi-phased university system integration project at a power plant producing 320,000 lb/hr of steam. This project initially began as furnishing water treatment controls along with burner management and combustion controls for two new boilers. Lipten was then hired to replace the BMS and CCS on two existing boilers. The project was complemented with new chilled water controls and a new, easy-to-use SCADA system integrating all the control systems into one reporting system.
Thermal Oxidizer to improve efficiencies and reduce emissions
Industry: Building Products
Lipten provided full EPC services to replace a thermal oxidizer, steam generator and related ancillary equipment damaged by hurricane Sandy. Not just satisfied with direct replacements, this new equipment allowed the plant to improve efficiencies, reduce emissions and meet all of the latest requirements set by the EPA. Lipten replaced a thermal oxidizer, ID Fan with VFD controls and waste heat recovery boiler. Two water damaged panel boards and a 480V/120V Transformer were also installed. Finally, Lipten designed and built a steel framed building to house the equipment. Once the design was finalized, site construction took only 85 days to complete.
Thermal Oxidizer and waste heat boiler Design/ Build
Industry: Building Products
Lipten provided design/build services for a new thermal oxidizer, waste heat boiler system and ancillary equipment. The thermal oxidizer is used to reduce air pollution emissions from a variety of industrial processes by incinerating the polluted exhaust gas prior to discharging the exhaust gas to atmosphere. The thermal oxidizer exhaust is routed through a waste heat boiler for production of saturated stream. The waste heat boiler is designed to produce 14,500 PPH of saturated 120-PSI steam at the maximum design waste gas inlet flow of 49,000 lbs/hr at 1,500°F.
Coal to Natural Gas Conversion on two Boilers
Lipten provided design/build services for a coal to natural gas conversion of two 150,000 lb/hr coal fired Riley Boilers. Lipten was responsible for all engineering, design, equipment, materials, demolition, construction and startup. The project included new fuel trains, burners, forced draft fans, induced draft fans, VFD’s, instruments and controls. Lipten also provided significant exhaust ducting modifications to bypass the coal exhaust gas emissions treatment equipment that was no longer needed when burner natural gas.
Restart of a plant that was mothballed for 10 years
Lipten helped restart a plant which was shutdown for over 10 years. Engineering and procurement services were provided to supply burners, fans, fuel trains, instruments, controls, installation, startup and training on four 40,000 lbs/hr watertube boilers. Lipten also provided an extensive “balance of plant” control and monitoring system. With Lipten’s assistance the plant is operating as if brand new.
Coal to Natural Gas conversion
Industry: Food & Beverage
Lipten provided design/build services for a coal to natural gas conversion of a 45,000 lb/hr coal fired boiler. Lipten was responsible for all engineering, design, equipment, materials, demolition, construction and startup. After installation, the existing baghouse control panel was modified to become the BMS panel and the existing coal fired control panel was modified to become the new CCS panel.
Engineering, Procurement and Construction Services for New Boiler
Lipten provided engineering and procurement services for a new 1,200 HP boiler. Civil engineering services were provided for the demolition and removal of existing plant equipment. Lipten engineered the specifications and civil work for the boiler, economizer, burner, fan, fuel train, stack and necessary platforms. In addition to this, Lipten provided new power distribution equipment and the necessary controls to manage the system.