SOx-NOx Reduction Project – Carbon Black
IAC served as the EPC contractor for Phase 2 of Tokai Carbon Black’s Sox-NOx Reduction Project in Addis, Louisiana, a key initiative to meet EPA Consent Decree requirements. Building on Phase 1 infrastructure, IAC was brought in to execute the mechanical, civil, and foundation scopes, delivering a high-performance system to reduce emissions and support long-term operational sustainability.
Key Project Components
Flue Gas Handling & SCR Integration:
- 128” diameter ductwork with three 1,500 HP ID fans (steam and electric powered)
- Duct heater and SCR system with ammonia injection to reduce NOx by ~90%
- Converter structure with steam drum and ASME B31.1 code process piping
Flue Gas Handling & SSO₂ to SO₃ Conversion SystemCR Integration:
- PTFE-lined process piping to condensers
- 20-module condenser assembly with glass tube technology
- Cooling gas fans (1,750 HP each) for heat removal
- Final clean gas stack: 12’ diameter, 173’ tall with air monitoring system
Sulfuric Acid Recovery & Storage:
- Production of 93%+ commercial grade sulfuric acid as a saleable byproduct
- Three stainless-steel storage tanks in concrete containment
- Pump system to transfer product to truck loading area
Foundations & Civil Work:
- Over 500 displacement piles installed in swamp-adjacent terrain
- More than 1,000 precision anchor bolts placed without rework
- Extended site work and berm construction to resolve water drainage challenges
Project Gallery
Results Delivered
Despite post-Covid supply chain delays and site challenges, IAC successfully delivered a high-performing system that reduced plant emissions below EPA-required levels. The integration of NOx reduction and sulfuric acid recovery systems not only improved environmental compliance but also generated a saleable byproduct stream for Tokai Carbon Black.
Why Partner with IAC
This project demonstrates IAC’s ability to adapt to changing project conditions, self-perform critical scopes, and manage complex EPC challenges under regulatory deadlines. By combining engineering, OEM equipment, and field execution, IAC delivered a turnkey solution that met both compliance and operational goals.
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IAC ECO Rapid Deployment Frac Sand Plant with views of Screeners and Thayer Feeders
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Turnkey Frac Sand Plants by IAC
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IAC ECO Rapid Deployment Frac Sand Plant with Screeners and Feeders
IAC ECO Rapid Deployment Frac Sand Plant with views of Screeners and Thayer Feeders
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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.
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IAC’s Newest Frac Sand Plant
Innovative project management pays off! Utilizing the huge experience portfolio from past 10 years in Frac Sand projects, IAC leverages real experience to deliver fully operational plant 5 WEEKS EARLY.
This new plant, located in Louisiana, USA boasts 1.5 MTPY production, and is designed to expand easily to 3.0 MTPY without any down time! While many northern plants are feeling the competitive squeeze on limited orders, there remains opportunities to deliver regional low cost, high quality frac sand supply; designed specifically for the local mine supply and end user requirements.
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IAC EPC Capabilities Video
IAC Makes Complex Projects Simple. Find out why IAC is the premier EPC - Engineer, Procure, Construct - Contractor for industrial projects such as baghouses, dust collection, ventilation systems, bulk material handling, pneumatic and mechanical conveying, rock and agricultural drying systems, bulk storage, automated controls for frac sand plants, cement plants and terminals, biomass plants, power generation plants, steel and secondary metal processing plants, transload facilities.
IAC also offers a Special OPS program to assist with systems optimization, employee training, and plant commissioning. For service after start-up, IAC has nationwide field service and maintenance crews to keep your process equipment and plants running at peak performance.
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Turnkey Frac Sand Plants by IAC
Turnkey Frac Sand Plants by IAC
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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
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Brochure
IAC is your single-source EPC contractor for complex industrial systems—from retrofitting dust collection systems to building out greenfield manufacturing lines. As an integrated engineering, procurement, and construction (EPC) provider, we […]
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IAC Full EPC Brochure
IAC Full EPC Brochure
IAC is your single-source EPC contractor for complex industrial systems—from retrofitting dust collection systems to building out greenfield manufacturing lines. As an integrated engineering, procurement, and construction (EPC) provider, we streamline every phase of your project—engineering, fabrication, construction, automation, and commissioning—under one roof.
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SOx-NOx Reduction Project – Carbon Black IAC served as the EPC contractor for Phase 2 of Tokai Carbon Black’s Sox-NOx Reduction Project in Addis, Louisiana, a key initiative to meet […]
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