innovative technologies for clean air - amec foster wheeler€¦ · innovative technologies for...

Innovative technologies for clean air

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1 Innovative Technologies for Clean Air

Dry Fork Station has the largest circulating fluidized bed scrubber in the world. The Amec Foster Wheeler system cleans 1.8 million cubic feet (51,000 cubic meters) of PC boiler flue gas every minute.

1 Innovative Technologies for Clean Air Innovative Technologies for Clean Air 2

A full line of clean air solutionsParticulate control uDry Electrostatic Precipitators uWet Electrostatic Precipitators uFabric Filters uCartridge Collectors

Acid gas and metal control uCirculating Fluidized Bed Scrubbers uSpray Dry Absorbers uDry Sorbent Injection uWet Flue Gas Desulfurization

NOx reduction uLow NOx Combustion Upgrades uSelective Catalytic Reduction

Services uRenewal Parts uPerformance Enhancements uSpecialty Products

Markets served uUtility Power Generation uIron and Steel uPulp and Paper uCement uMining Industries uFoundry uPetroleum uChemical uRefuse-to-Energy uCogeneration


Particulate Control

VIGR Dry ESP uVariable intensity gravity rapping

for optimized plate cleaning uCompact casing, no moving

parts in air stream

FPL Martin & ManateeLocation: Martin & Manatee, FL, USACustomer: Florida Power & LightDesign: 4 x VIGR ESPPlant Capacity: 4 x 800 MWeStart-Up Year: 2012-2015Fuel: No. 6 Fuel OilGas Flow: 4 x 2,958,000 ACFM

(4 x 5,025,673 m3/hr)PM Removal: 95%

Santee Cooper CrossLocation: Cross, SC, USACustomer: Santee CooperDesign: 4 x HaRDE ESPPlant Capacity: 2 x 600 MWeStart-Up Year: Unit 3/4 - 2007/08Fuel: Bituminous CoalGas Flow: 4 x 1,050,000 ACFM

(4 x 1,783,961 m3/hr)PM Removal: 99.9%

HaRDETM Dry ESP uHigh intensity tumbling hammer

rapping for tenacious dust uClean roof, no penetrations

minimizes in-leakage and corrosion

Pennsylvania Power & Light MontourLocation: Washingtonville, PA, USACustomer: Pennsylvania Power & LightDesign: 4 x VIGR ESPPlant Capacity: 2 x 750 MWeStart-Up Year: Unit 1/2 – 2001/02Fuel: Bituminous CoalGas Flow: 4 x 1,400,000 ACFM

(4 x 2,378,615 m3/hr) PM Removal: 99.9%

Cinergy (Duke) CayugaLocation: Cayuga, IN, USACustomer: Cinergy (Duke)Design: 4 x VIGR ESPPlant Capacity: 2 x 525 MWeStart-Up Year: Unit 1/2 – 2005/06Fuel: Bituminous CoalGas Flow: 4 x 1,050,000 ACFM

(4 x 1,783,961 m3/hr) PM Removal: 99%

Electrostatic PrecipitatorsDry Electrostatic Precipitators

Amec Foster Wheeler offers two Dry Electrostatic Precipitator (ESP) designs for industrial or utility applications.

Our Hammer Rapped Rigid Discharge Electrode (HaRDETM) and Variable Intensity Gravity Rapped (VIGR) designs feature our virtually unbreakable rigid discharge electrodes and a full penthouse for ease of maintenance, increased performance and enhanced reliability.

RECENT PROjECTS

51 GWe of utility applications and a broad range of fuels and processes


Horizontal Wet ESP uWide range of gas volumes uIrrigated plates allow

continuous cleaning

Wet Electrostatic Precipitators

Condensing Vertical Wet ESP uCompact rectangular or round

designs uIrrigated tubes allow continuous

cleaning

Peabody Prairie StateLocation: Lively Grove, IL, USACustomer: Prairie State EnergyDesign: 2 x Plate Horizontal FlowCapacity: 2 x 800 MWeStart-Up Year: 2011Fuel: Bituminous CoalGas Flow: 2 x 2,265,000 ACFM

(2 x 3,848,259 m3/hr)

LG&E Trimble County 2Location: Trimble County, KY, USACustomer: LG&EDesign: Plate Horizontal FlowCapacity: 750 MWeStart-Up Year: 2010Fuel: Bituminous,

Sub-Bituminous CoalGas Flow: 2,100,000 ACFM

(3,567,922 m3/hr)

City of Springfield DallmanLocation: Springfield, IL, USACustomer: City of SpringfieldDesign: Plate Horizontal FlowCapacity: 200 MWeStart-Up Year: 2009Fuel: Bituminous CoalGas Flow: 640,000 ACFM

(1,087,366 m3/hr)

PCS Phosphate AuroraLocation: Aurora, NC, USACustomer: PCS PhosphateDesign: Tubular Vertical FlowStart-Up Year: 2001-2003Gas Source: Phosphate CalcinersGas Flow: 6 x 71,600 ACFM

(6 x 122,000 m3/hr)

Wet Electrostatic Precipitators (WESP) are polishing devices to remove fine particles and condensed aerosols such as sulfuric acid mist.

We offer both a horizontal flow design for large utility and industrial applications and a vertical flow modular design for smaller applications.

RECENT PROjECTS

We have supplied the world’s largest WESPs up to 800 MWe single unit capacities.

uAlloy construction uDurable rigid discharge electrodes uFull penthouse/insulator enclosure uIntermittent spray washing capability

as secondary means of cleaning

Our advanced design continuously washes the collection plates with a special irrigation design allowing uninterrupted power to all plates resulting in excellent capture performance and a compact design.


Southern Company Scherer Units 1 - 4Location: Monroe County, GA, USACustomer: Southern CompanyDesign: 4 x Jet VIPPlant Capacity: 4 x 818 MWeStart-Up Year: Units 1-3/4 – 2009/10Fuel: Sub-Bituminous Coal Gas Flow: 4 x 3,774,160 ACFM

(4 x 6,412,338 m3/hr)PM Removal: 88.8% (Polishing units)

Jet VIP Intermediate Pressure uIntermediate 35 psig (2.4 bar)

pressure for optimized cleaning uCustom designed for bags up

to 32.8 ft (10 m) for large utility and industrial applications

uSplit-gas inlet baffle to minimize can velocity and dust re-entrainment

uLow pulse cleaning frequency for long bag life

Fabric Filters

Jet III High Pressure uHigh pressure, 90 psig (6.2 bar)

cleaning for compact designs uStandardized, modular design

with bags up to 16 ft (4.9 m) for a wide range of industrial applications

uHigh efficiency inlet “Sinto” baffle for optimal gas and dust distribution

We offer Fabric Filter designs for both industrial and utility applications, serving as primary, secondary or polishing particulate control devices.

Our installed experience spans the full range of filter media types and cleaning methods (shaker, reverse air, high and intermediate pressure pulse jet). uDrawn cup tubesheet to enhance

bag seal, or “standard” laser-cut tubesheet

uOptimized cleaning system with variable-hold manifold pipes for equal cleaning to all bags

uOn-line maintenance for operational flexibility

CPS San Antonio Deely 1-2Location: San Antonio, TX, USACustomer: Public Service of San AntonioDesign: 4 x Reverse Air Plant Capacity: 2 x 430 MWeStart-Up Year: Units 1/2 – 2007/06Fuel: Coal Gas Flow: 4 x 900,140 ACFM (4 x 1,783,961 m3/hr)PM Removal: 99.8%

Particulate Control

US Steel Granite CityLocation: Granite City, IL, USACustomer: US Steel Granite City Design: Jet IIIStart-Up Year: 2015Gas Source: Basic Oxygen FurnaceGas Flow: 900,000 ACFM (1,529,110 m3/hr)PM Removal: 99.9%Product Collected: Iron Oxide

RECENT PROjECTS

Our Jet VIP design offers the lowest bag cleaning frequency on the market.*

*Source: EPRI’s Pulse-Jet Fabric Filter Guidelines Report


Cartridge CollectorsCost-efficient small scale dust control

Applications uFerrous and non-ferrous metals u Material handling, transfer points,

bucket elevators u Grinders, descalers, crushers u Blast machines, air blast rooms u Casting lines u Metallurgical fumes u Silo bin vents uMining and rock products u Material handling u Ore preparation, crushers, screens u Silo bin vents uChemical and food products u Material handling u Banbury mixers u Silo bin vents uMiscellaneous u Welding fumes u Atmospheric air u Wood dust u Flyash

uLow capital cost uLow freight and install cost uNo cages or filter hardware uLow overall height uReduced foundations and

support steel uCompact, lightweight design

Doe Run Sweetwater MillLocation: Ellington, MO, USACustomer: Doe Run CompanyDesign: Cartridge CollectorStart-Up Year: 2013Gas Flow: 190,000 ACFM

(323,000 m3/hr)Product Collected: Nuisance dust

Patented locking mechanism for simple, easy filter element replacement from outside the unit

There are no bags, cages, clamps or hardware to be replaced during an element change out.

RECENT PROjECTS

UndisclosedLocation: Indiana, USACustomer: UndisclosedDesign: Cartridge CollectorStart-Up Year: 2011Gas Flow: 10,750 ACFM

(18,264 m3/hr)Product Collected: Nuisance dust


WaterHydrated Lime

Flue Gas and Fly Ash

Air

Solid By-product

Air

AbsorberuSelf-cleaning CFB

process minimizes maintenance

uCarbon steel design avoids expensive liners and alloys

uMultiple venturi design allows wide range of capacities

uLong gas and solid mixing time for high pollutant capture and maximum lime utilization

Solid Recirculationu Reliable non-mechanical air slide proven

by years of use in the power industry

Fabric FilteruOptimized pulse

frequency across filter sectors allows efficient solid recirculation, dust capture and long bag life

Absorber BottomuFlue gas inlet chamber drops out large particles

Rotary Valve

Shut Down Valveu Fast acting shut down valve to allow purge

of absorber solids during a boiler trip

Basin Electric Dry Fork StationLocation: Gillette, WY, USACustomer: Nooter EriksonDesign: 1 Reactor + 2 Fabric FiltersPlant Capacity: 420 MWeStart-Up Year: 2011Fuel: PRB CoalGas Flow: 1,800,000 ACFM

(3,060,000 m3/hr)SO2 Removal: Up to 96%SO3 Removal: Up to 99%HCl Removal: Up to 67%

Refinery Wesseling GermanyLocation: Wesseling, GermanyCustomer: UndisclosedDesign: 2 x (Reactors + Fabric Filters)Plant Capacity: 2 x 60 MWe Start-Up Year: 2012Fuel: Heavy Fuel OilGas Flow: 2 x 225,000 ACFM

(2 x 382,500 m3/hr)SO2 Removal: Up to 97%SO3 Removal: Up to 99%

Harbin Electric Soma KolinLocation: Soma, TurkeyCustomer: Harbin Electric InternationalDesign: 2 x (Reactors + Fabric Filters)Plant Capacity: 2 x 225 MWeStart-Up year: 2016Fuel: Turkish LigniteGas Flow: 2 x 716,000 ACFM

(2 x 1,217,200 m3/hr)SO2 Removal: 79%SO3 Removal: 95%HCl Removal: 90%HF Removal: 77%

Circulating Fluidized Bed ScrubberA Flexible multi-pollutant technology

Acid Gas & Metal Control

RECENT PROjECTS

We have supplied 78 units cleaning over 7 GWe of flue gas in power and industrial facilities.


Basin Electric Dry Fork StationLocation: Gillette, WY, USACustomer: Nooter EriksonDesign: 1 Reactor + 2 Fabric FiltersPlant Capacity: 420 MWeStart-Up Year: 2011Fuel: PRB CoalGas Flow: 1,800,000 ACFM

(3,060,000 m3/hr)SO2 Removal: Up to 96%SO3 Removal: Up to 99%HCl Removal: Up to 67%

Amec Foster Wheeler offers both open tower and Dual Flow Tray (DFT) Wet Flue Gas Desulfurization (WFGD) technology.

Wet Flue Gas Desulfurization

Dallman Station, Unit 33Location: Springfield, IL, USACustomer: City of SpringfieldDesign: DFT AbsorberPlant Capacity: 192 MWeStart-Up Year: 2011Fuel: Illinois Bituminous CoalGas Flow: 913,000 ACFM

(1,552,100 m3/hr)SO2 Removal: Up to 98%

PSNH Merrimack Station, Units 1-2 Location: Bow, NH, USACustomer: Public Services of NHDesign: DFT AbsorberPlant Capacity: 457 MWeStart-Up Year: 2012Fuel: Bituminous CoalGas Flow: 1,628,000 ACFM

(2,767,600 m3/hr)SO2 Removal: Up to 97%HF, HCl Removal: Up to 99%Hg Removal: Up to 86%

RECENT PROjECTS

TECO Big Bend Station, Units 1-2 Location: Apollo Beach, FL, USACustomer: TECODesign: DFT AbsorberPlant Capacity: 2 x 445 MWeStart-Up Year: 1999Fuel: Petcoke, Eastern Bituminous CoalGas Flow: 2,800,000 ACFM

(4,760,000 m3/hr)SO2 Removal: Up to 95%HF, HCl Removal: Up to 99%

Dual Flow Tray (DFT) uDFTs dramatically improve

absorber performance well beyond open tower designs

u Lower liquid to gas ratio u Smaller footprint u Optimized flue gas distribution u Easier absorber maintenance u Lower capital cost uMultiple DFTs can be provided to

improve performance on both new and existing WFGDs

uIntegral absorber and recycle tank uSelf-supported internal recycle headers provide optimal slurry

distribution within the absorber zone uAbsorber vessels are custom designed to meet clients’ needs uExperience with all absorber materials (alloys, cement, rubber

and glass linings) uFull range of reagent and by-product experience uBroad experience in upgrading existing WFGDs

Retrofitted 4.5 GWe of existing FGDs.

Delivered 22 GWe of new FGDs.


Spray Dry Absorbers

Acid Gas & Metal Control

These specially designed nozzles produce a dense mist of fine droplets that efficiently captures acid and heavy metal gases, locking them into a dry solid for removal by downstream particulate control system.

We have applied our SDA technology to a wide range of utility and industrial applications for control of acid and heavy metal gases (SO2, SO3, HCl, HF, Hg).

Baldwin Generating Station, Units 1-3 Location: Baldwin, IL, USACustomer: DynegyDesign: 6 x (SDAs + Pulse Jet FFs)Capacity: 3 x 600 MWeStart-Up Year: 2010Fuel: Sub-bituminous coalGas Flow: 6 x 1,239,423 ACFM

(6 x 2,105,793 m3/hr)SO2 Removal: Up to 90%

Dominion Brayton PointLocation: Somerset, MA, USACustomer: Dominion EnergyDesign: 2 x (SDAs + Pulse Jet FFs)Capacity: 2 x 250 MWeStart-Up Year: 2007Fuel: CoalGas Flow: 2 x 994,268 ACFM

(2 x 1,689,272 m3/hr)SO2 Removal: Up to 90%

RECENT PROjECTS

uAbsorber design optimizes flue gas distribution and gas/reagent residence time to maximize performance

uSystem provides low maintenance and installed cost

uAchieves low load without flue gas bypass or recirculation

uQuick response to fuel variations and boiler load changes

Next Generation Two-Fluid Nozzles uOur nozzles operate

longer between cleanings than any others available on the market.

uEasy online nozzle changeout minimizes maintenance time.

uTungsten carbide inserts provide long nozzle life

uLow air usage reduces air system installation and operating cost

JEA Northside Generating Station Location: Jacksonville, FL, USACustomer: Jacksonville Electric AuthorityDesign: 2 x (SDAs + Pulse Jet FFs)Capacity: 2 x 300 MWeStart-Up Year: 2002Fuel: Petcoke, CoalGas Flow: 2 x 836,500 ACFM

(2 x 1,422,050 m3/hr)SO2 Removal: Up to 90%SO3 Removal: Up to 99%HCl Removal: Up to 99%

Our Spray Dry Absorber (SDA) utilizes advanced two-fluid atomizing technology.

We have supplied 60 units cleaning over 4.5 GWe of

flue gas.


We have provided 92 GWe of low NOx combustion solutions to wall, tangential, and arch fired furnaces.

We improve the performance of your mills, coal/air delivery system, burners, and overfire air system for an optimized economic solution.

NOx Reduction

Combustion Upgrades

SCG Hammond Unit 2 Location: Coosa, GA, USACustomer: Georgia Power Co.Design: Dual zone OFA ports,

VS/SF LNB systemCapacity: 540 MWe Start-Up Year: 2014Fuel: Bituminous coalNOx Reduction: Over 65%CO Emission: Under 100 ppm

TSE Naantali 3Location: Naantali, FinlandCustomer: Turun Seudun

Energiantuotanto Oy (TSE)Desgin: Hot-side SCR (2+1)Capacity: 315 MWe Start-Up Year: 2015Fuel: Coal and BiofuelNOx Reduction: 70%Ammonia Slip: Under 5 ppm

Orot RabinLocation: IsraelCustomer: Israel ElectricDesign: TLN3 SOFA systemCapacity: 572 MWeStart-Up Year: 2015Fuel: CoalNOx Reduction: Over 70%CO Emission: Under 100 ppm

RECENT PROjECTS

We have supplied over 130 selective catalytic reduction (SCR) systems globally for a variety of applications including pulverized-coal utility boilers, industrial process heaters and boilers, and combustion turbines.

uPatented in-duct ammonia vaporizer uSimplified catalyst loading/unloading system uSimplified Ammonia Injection Grid (AIG) design uIntegrated AIG/mixer design uLay-up system for catalyst protection uEconomizer bypass for low load operation

Advanced 6-lobe Opti-Flow low NOx burner for wall-fired boilers.

Proven double shroud low NOx burner for T-fired boilers.

Selective Catalytic Reduction

Innovative Technologies for Clean Air 11Dec14

Amec Foster Wheeler’s Global Power Group offers a full range of steam generator equipment, clean air technologies, aftermarket products and services to the power, industrial, and waste-to-energy sectors. GPG’s global engineering, manufacturing, and procurement network delivers high-quality, cutting-edge products and services cost competitively, no matter where the project is located.

Contact Us

Steam Generators uCirculating Fluid Bed uPulverized Coal uOil & Gas uSolar uBubbling Fluid Bed uPackage uGrate and MSW uWaste Heat uHRSG

Environmental Products uWet FGD systems uCFB scrubbers uDry Sorbent Injection uSpray Dry Absorbers uWet and dry ESPs uFabric filters uCartridge collectors uLow NOx combustion

and SCR retrofits

Aftermarket Services uEngineered pressure parts uReplacement parts uWeld overlays uRefractory upgrades uCoal mill service and upgrades uConstruction Services uPerformance upgrades uBoiler retrofits

Auxiliary Equipment uCondensers uFeedwater heaters uBiomass gasifiers

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