Greenfield Frac Sand Plant
IAC served as the EPC contractor for High Roller Sand’s greenfield frac sand (dry) plant in Kermit, Texas, delivering one of the most advanced frac sand facilities in the U.S. With a capacity of 4.5 million tons per year, the project was designed and built in nearly half the time of comparable plants, demonstrating IAC’s ability to meet aggressive market demands.
Key Project Components
- Engineering and design of the full dry plant
- Equipment design, fabrication, and installation
- Automated controls, PLC, and MCC for plant-wide monitoring and optimization
- Storage silos totaling 18,000 tons
- Mechanical and electrical construction
- Commissioning and start-up
- Project duration: 7 months
Photo Gallery
Results Delivered
The High Roller Sand facility is recognized as one of the most advanced frac sand plants built in the U.S.. IAC’s EPC delivery model enabled the project to be completed on a fast-track schedule, achieving full commissioning in just seven months.
Why Partner with IAC
IAC combines decades of frac sand industry experience with OEM equipment expertise and construction capabilities. This integrated approach ensures rapid project delivery without sacrificing quality or long-term reliability.
Internal Reference: E18146
Videos
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In Part 2 of IAC’s “Key Parts of a Baghouse” series, IAC's Joe Haney takes a closer look at the…
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about Tip of the Month: Parts of a Baghouse Part 2
IAC offers complete Frac Sand Dry Plant solutions. Our expert engineers and process equipment specialists are available for everything from…
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about IAC Complete Frac Sand Dry Plant Solutions
IAC contracted with a Waste-to-Energy facility adjacent to a US Army Arsenal to remove and install 12 baghouse modules. The…
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about IAC STAINLESS STEEL BAGHOUSEWASTE REPLACMENT FOR A WASTE-TO-ENERGY PLANT – 2017
IAC was awarded a $50 million EPC contract to supply a variety of systems at the Drake Cement, Greenfield, Arizona…
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about Single Pass Separator Project
IAC is an Engineering, Procurement, and Construction (EPC) Contractor and Original Equipment Manufacturer (OEM) of Baghouses, Dust Collectors, Pneumatic Conveying…
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about IAC Solutions for Cement Plants and Terminals
EPC
Tip of the Month: Parts of a Baghouse Part 2
In Part 2 of IAC’s “Key Parts of a Baghouse” series, IAC's Joe Haney takes a closer look at the critical components that keep your industrial dust collection system performing efficiently and in compliance. From filter bags and cages to pulse valves and differential pressure gauges, learn how each part contributes to reliable operation and optimal airflow.
Whether you’re a plant engineer, maintenance planner, or operations manager, understanding how your baghouse works helps you reduce downtime, extend filter life, and ensure emissions compliance.
What You’ll Learn:
How pulse cleaning systems maintain filter efficiency
The role of cages, bags, and venturis in dust filtration
Common signs of wear and when to replace key components
Maintenance best practices to improve uptime
Watch Part 1 here: https://www.youtube.com/watch?v=kkR2AWv-Oe4
Don't forget to subscribe to our channel to see more IAC Tip of the Month Videos!
EPC
IAC Complete Frac Sand Dry Plant Solutions
IAC offers complete Frac Sand Dry Plant solutions. Our expert engineers and process equipment specialists are available for everything from designing & building a complete plant, to onsite maintenance and troubleshooting services and optimization of process equipment, to engineering evaluations and inspections. IAC also supplies replacement spare parts.
EPC
IAC STAINLESS STEEL BAGHOUSEWASTE REPLACMENT FOR A WASTE-TO-ENERGY PLANT – 2017
IAC contracted with a Waste-to-Energy facility adjacent to a US Army Arsenal to remove and install 12 baghouse modules. The facility processes 690 tons of solid waste and sewage sludge per day, producing energy for the arsenal’s heating and air conditioning needs. The facility opened in 1990 and when it was determined that the original two baghouses needed to be replaced, IAC was awarded an EPC contract in April, 2017 to design, supply and install the new baghouses.
EPC
Single Pass Separator Project
IAC was awarded a $50 million EPC contract to supply a variety of systems at the Drake Cement, Greenfield, Arizona Plant.
The install included silos, clinker handling, conveyors, waste product silo and additional fugitive collection systems for each.
This project required construction trades on site for over a five year period. The project incorporates $20 million EPC contract for a High Efficiency Separator.
For more information about all IAC can do, call us today at 800.334.7431 or visit us online at https://iac-intl.com
IAC, let's build something incredible.
EPC
IAC M Pulse Baghouse
EPC
IAC Solutions for Cement Plants and Terminals
IAC is an Engineering, Procurement, and Construction (EPC) Contractor and Original Equipment Manufacturer (OEM) of Baghouses, Dust Collectors, Pneumatic Conveying Systems, Heat Exchangers, and more for Cement Industry Plants and Terminals.. We also design and build Dry Bulk Storage Silos and Domes, and fully automated Transload and Truck Loadout Facilities.
Contact us today by calling 913-384-5511 to discuss your next greenfield build or capital improvement project.
Articles
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Learn how to install a snap band filter bag in your baghouse's tubesheet the right way so that it seats correctly and does not allow emissions to escape.
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about How to Install Snap Band Filter Bags the Right Way – Baghouse Tip
Do you know what the biggest performance killer for a baghouse ventilation system is? It’s in leakage, when air seeps into a ventilation system.
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about The Effects of Air Leakage in a Baghouse Ventilation System – IAC
IAC offers a winterizing kit for pulse jet baghouses to prevent operational disruptions due to freezing conditions. The kit protects crucial components, ensuring reliable cleaning and maintenance, thus maintaining production efficiency during winter.
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about Pulse Jet Baghouse Winterization Kits and Service
Properly monitoring baghouse differential pressure will keep your industrial ventilation system working to meet required production rates.
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about Tip of the Month: Properly Monitoring Baghouse Differential Pressure
IAC Field Engineer Luis Castano explains the differences between a baghouse and a filter receiver.
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about Filter Receiver Versus Baghouse – IAC Blue Crew Field Services
Is the HEPA filter in your Baghouse industrial ventilation system located before or after the fan? Learn the importance of correct placement in this video.
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about Tip of the Month: Correct Placement of HEPA Filters in Baghouse Ventilation System
Brochures
The IAC Sonic Horn Catalog is a product-focused guide showcasing IAC’s full line of sonic horn solutions for dust removal and material flow improvement. It is designed for engineers, maintenance […]
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about IAC Sonic Horn Catalog
The IAC Broken Filter Bag Detector Installation Manual provides clear, step-by-step guidance for installing, configuring, and maintaining IAC’s Dust Monitor systems. Designed with plant managers, operators, and maintenance teams in […]
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about IAC Broken Filter Bag Detector Installation Manual
IAC Sonic Horn Catalog
IAC Sonic Horn Catalog
The IAC Sonic Horn Catalog is a product-focused guide showcasing IAC’s full line of sonic horn solutions for dust removal and material flow improvement. It is designed for engineers, maintenance teams, and plant operators looking for efficient, low-maintenance cleaning systems. The catalog highlights:
- Product range: Various sonic horn models, frequencies, and sizes tailored for different industrial applications.
- Applications: Effective in baghouses, silos, hoppers, heat exchangers, and ductwork—where they prevent buildup, bridging, and fouling.
- Technical specifications: Frequency ranges, power requirements, construction materials, and performance data to aid in system selection.
- Benefits: Reduced downtime, longer filter life, better airflow, improved heat transfer efficiency, and lower maintenance costs.
- Integration support: Guidance on where and how to apply sonic horns within existing process systems for maximum effectiveness.
Overall, the catalog positions sonic horns as a cost-effective, non-invasive alternative to mechanical cleaning systems, helping plants improve uptime, reduce operating expenses, and enhance environmental compliance.
IAC Broken Filter Bag Detector Installation Manual
IAC Broken Filter Bag Detector Installation Manual
The IAC Broken Filter Bag Detector Installation Manual provides clear, step-by-step guidance for installing, configuring, and maintaining IAC’s Dust Monitor systems. Designed with plant managers, operators, and maintenance teams in mind, the manual covers:
- Installation instructions: Proper mounting, wiring, and calibration for reliable system performance.
- Operation guidance: How to monitor particulate levels, interpret system signals, and integrate readings with existing plant controls.
- Maintenance best practices: Routine checks, troubleshooting tips, and service recommendations to ensure long-term accuracy and uptime.
- Safety and compliance support: Ensures proper use of monitoring equipment to help plants maintain air quality standards and meet regulatory requirements.
Projects
Biocarbon Facility for Green Steel – Mississippi IAC is serving as the EPC partner for SDI BioCarbon Solutions, delivering a new biocarbon production facility that will supply renewable carbon for […]
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about Biocarbon Facility for Green Steel – Mississippi
Project Overview IAC executed a full EPC project to design and install lead oxide dust containment systems for a large battery manufacturing facility in Missouri. The scope included advanced engineering, […]
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about EPC Lead Oxide Dust Containment Battery Manufacturer – Missouri
Greenfield Frac Sand Plant IAC served as the EPC contractor for High Roller Sand’s greenfield frac sand (dry) plant in Kermit, Texas, delivering one of the most advanced frac sand […]
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about Greenfield Frac Sand Plant – Texas
Greenfield Flat Roll Steel Plant IAC completed an EPC turnkey ventilation and dust control system for the melt shop at Steel Dynamics’ new greenfield flat-roll steel mill in Sinton, Texas. […]
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about Steel Dynamics – Greenfield Flat Roll Steel Plant – Texas
Project Overview Since 2012, IAC has executed multiple EPC projects for Drake Cement’s production facility in Paulden, Arizona. These efforts have supported plant expansion, improved dust collection, and ensured compliance […]
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about Drake Cement Plant Expansion – Arizona
The Nucor Steel, South EAF turnkey project included an IAC M-Pulse Baghouse rated at 1,200,000 acfm at 250 degrees F, 150’ tall Outlet Stack, Load-out Silo with Receiver Filter, MCC […]
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about Nucor Steel
Industries
Lime Production & Processing Lime production is an essential component in steelmaking, construction, water treatment, and environmental control. With demanding operating conditions and tightening emissions regulations, lime producers require engineered […]
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about Lime Production & Processing
Engineering Performance for Modern Frac Sand Operations Frac sand plants operate under high pressure to deliver consistent throughput, reduce fuel cost per ton, and maintain strict silica dust compliance. IAC […]
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about Frac Sand & Proppants