Spray Dryer Absorber, Pulse Jet Fabric Filter and Mercury Control Systems — Keephills Unit 3 Plant

Success Story

TransAlta and Capital Power

Wabamun, Alberta, Canada

Contract Order: 2007

Commercial Operation: 2011

Overview

Babcock & Wilcox spray dryer absorber (SDA) systems feature a combination of design components to provide a level of reliability and sulfur dioxide (SO2) removal efficiencies that are among the highest in the industry.

B&W is the exclusive North American licensee of GEA Process Engineering A/S, Denmark, for the GEA Niro SDA process. The GEA Niro SDA is globally recognized by the power generation industry as the dry scrubber technology of choice.

Features of the system include a unique flue gas dispersion system for optimal gas and reagent mixing, a low maintenance rotary atomizer with a slurry capacity that is among the highest in the industry, large SDA chambers, and a complete reagent recycle system. Benefits include high SO2 removal efficiency, low capital cost, high system availability, and low operation and maintenance costs.

Download Case Study (PDF)

Boiler/Plant Information:

Unit 3:

495 MW

Boiler type:

Hitachi supercritical pulverized coal with natural gas for startup

Design fuel:

Western subbituminous

Project Summary

B&W's project scope includes an SDA system to limit SO2 emissions, consisting of 2 x 50% SDA vessels and reagent preparation system (for lime and recycle ash), a pulse jet fabric filter (PJFF), and a sorbent injection system using powdered activated carbon (PAC) to limit mercury emissions.

B&W Scope

• Two SDA modules, size 10000 (16 meter)
• Two Niro F800 rotary atomizers
• SDA inlet and interconnecting flues
• Lime preparation system with paste slakers
• Recycle solids preparation system
• Eight compartment plenum style PJFF with integral bypass
• PPS/P84 filter bags
• Pulse air cleaning system
• Sorbent injection system for mercury control using PAC reagent

Results

• Met all performance and reliability run guarantees
• Project was structured using a variable price/fixed price arrangement and was executed on budget and below the original price estimate

3D Projection of Keephills Unit 3 SDAs and Pulse Jet Fabric Filter