Grey Engineering Enterprises
Overview of the steam plant project area with insulated ducting, boiler stack, and new vessels
Current Project · Iowa, USA

Climax Molybdenum
Steam Plant Renewal

Location
Iowa, USA
Role
EPC — Turnkey
Status
In Progress
Setting
Operating Plant
Project Brief

A full steam plant, rebuilt in place

At the Climax Molybdenum plant in Iowa, Grey Engineering Enterprises is executing a complete steam plant renewal inside an operating facility. The scope replaces the heart of the plant — deaerator, steam drum, and steam boiler — while relining the sulfur furnace with new refractory fire brick and renewing insulation systems throughout.

The project also closes out a problem that predates it: boiler feed water pumps that had vibrated and starved for flow for years. Our hydraulic flow studies and ASME pipe stress analysis identified the root causes, and the corrected piping, supports, and pump installations now run smooth.

Discuss a Similar Project
01

Deaerator Replacement

Complete deaerator design and construction — demolition of the existing unit, new deaerator and storage section set inside the existing structure, trim, relief valves, and piping tie-ins.

02

Steam Drum Replacement

New steam drum engineered, fabricated, rigged, and set with safety relief valves and flanged nozzles verified against existing piping.

03

Steam Boiler Replacement

Steam boiler replacement including tube sheet work, retube activities, combustion ducting, and insulated flue-gas connections to the stack.

04

Sulfur Furnace Refractory Reline

Full refractory fire brick reline of the sulfur furnace — demolition, radial brick courses to engineered tolerances, and controlled dry-out.

05

Insulation Systems

New insulation and jacketing across vessels, ducting, and piping — engineered for thermal movement and weather exposure.

06

BFW Pump Vibration & Flow Resolution

Historic boiler feed water pump vibration and flow problems diagnosed and eliminated through hydraulic flow studies and ASME pipe stress analysis, with corrected piping and support arrangements.

Field Photography · 22 Frames

From the jobsite

Click any frame to enlarge
New deaerator and steam drum vessels installed among plant piping at the Climax Molybdenum plant in Iowa
New pressure vessels set in the steam plant — deaerator and steam drum replacement
Replacement deaerator vessel installed with new piping and valves at the Iowa Climax Molybdenum facility
Deaerator replacement installed within the existing structure
New steam drum with safety relief valves and flanged nozzles prior to final piping tie-ins
New steam drum with safety relief valves, ready for tie-in
Sterling deaerator storage vessel installed with new ladder access and blue gate valve
Deaerator storage section set with new access and trim
Blowdown separator vessels and new piping installed on elevated steel platforms
Blowdown separators and interconnecting piping on new supports
New boiler feedwater piping, control valves, and vessel trim installed at the steam plant
Boiler feedwater piping and control valve stations
Overview of the steam plant project area with insulated ducting, boiler stack, and new vessels
Steam plant overview — boiler, ducting, and new vessel installation
Aerial view of steam boiler replacement area with insulated stack ducting and scaffolding
Boiler replacement work area with new insulated ducting
New insulated flue gas ducting routed to the boiler stack at the Climax Molybdenum plant
New insulated flue-gas ducting and stack connection
Insulated boiler ducting elbows and jacketing with yellow access stairs
Ducting, jacketing, and insulation detail at the boiler outlet
Fire-tube steam boiler open for retube with tube sheet exposed behind scaffolding
Steam boiler open for inspection and retube
Boiler tube sheet detail during steam boiler replacement at the Iowa plant
Tube sheet detail during boiler replacement
Heat exchanger tube bundle and tube sheet during fabrication and inspection
Exchanger tube sheet during inspection
Refractory fire brick staged at the sulfur furnace with ventilation and mortar equipment
Refractory brick staged for the sulfur furnace reline
Refractory crew installing fire brick inside the sulfur furnace shell
Refractory crew bricking the sulfur furnace
Radial refractory brick arch courses inside the sulfur furnace during reline
Radial brick courses inside the furnace
Refractory brick lining progress viewed through the furnace manway
Brick lining progress through the furnace opening
Brick saw station and scaffolding at the sulfur furnace refractory installation
Cut station and access scaffold at the furnace
New insulation and jacketing installed on vessels with yellow access stairs
New insulation and jacketing on vessels and piping
Rebuilt boiler feedwater pumps with new suction and discharge piping after vibration resolution
Boiler feed water pumps — vibration and flow problems resolved
New deaerator vessel being set and rigged into position at the Iowa Climax Molybdenum steam plant
Deaerator set and rigged into position at the steam plant
Fabricated pressure vessel with flanged nozzles and saddle supports delivered to the Iowa plant site
Pressure vessel delivered to site — flanged nozzles and saddle supports
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