A Recent Case Study ofWet FGD Performance Improvements

At B.L. England Unit 2 using

ALRD® Technology

Presenters:Amy Evans, Marsulex Environmental Technologies

Dennis Del Vecchio, NAES Corporation

BL England Staff & Management– Eric Adolfsen | BL England Plant Engineer– Dennis Prichett | BL England Scrubber Supervisor

Authors– Mike Hammer | Marsulex Environment Technologies– Amy Evans | Marsulex Environment Technologies– Dennis Del Vecchio | NAES / RC Cape May Holdings– Gary Andes | WorleyParsons

Acknowledgments

Plant Background and Administrative Consent Order (ACO)Upgrade OptionsImplementation and ConstructabilityPerformance ResultsConclusions

Agenda

B.L. England

Cape May County, NJ on the Great Egg Harbor River450 MW plant3 generating units (2 coal, 1 oil)Unit 2– 155 MW, balanced draft– Equipped with FGD, ESP, LNB, SNCR– Eastern bituminous coal (3.2% S)

FGD LSFO Wallboard grade gyp, sold locally– Retrofitted in 1994 with open spray tower WFGD system– Designed for 93% SO2 removal

Administrative Consent Order

Issued date: 2006Issued by: New Jersey Department of Environmental ProtectionRequirement: Increase SO2 removal efficiency to 97% while firing 3.2% ( 5.11 lbs SO2/MM Btu) sulfur bituminous coal.

– Emission limit of 0.15 lbs SO2/MMBtu on a 30 day rolling avg– Emission limit of 0.25 on a 24 hour basis

Deadline: May 2010Project Requirements:

– Meet emission limits– Do not adversely impact particulate emissions– Do not adversely impact ME carryover from the absorber

Options Considered

Chemistry changes“Traditional” MethodsALRD® | Absorber Liquid Redistribution Device

ALRD Technology

Aspects:Commercially demonstrated technologyIncreases L/G contact

— Solves wall effect and re-entrains and re-activates wall slurry

— Solves flue gas “sneakage” along absorber wall

Minimal effect on flue gas pressure drop

ALRD Technology

Recommended technology for B.L. England Unit 2:Two ALRD levels determined to meet removal requirementsCould be incorporated into two scheduled outagesDetermined most cost and schedule effective method

ALRD ImplementationEngineering, procurement and fabrication in 12 weeks

Designed to enable installation within scheduled outages

Items were fabricated in shop– Shop Fab Details:

Carbon Steel mounting plate welded to Alloy support brackets. ALRD Plates laser cut in the shop

– Field Details: Carbon Steel mounting plates eliminated the need for certified alloy

welders in the field– Better fit-up and quality control

Design included two ALRD levels with support brackets & rubber lining

ALRD ImplementationLocation critical to meet design requirements― Level 1

2nd and 3rd absorber spray levels 30 brackets and 28 sections

― Level 2 3rd and 4th absorber spray levels 29 brackets and 27 sections

A phased approach was utilized for field installation– ALRD level 2 was installed during Fall 2009 outage, 12 days– ALRD level 1 was installed during Spring 2010 outage, 25 days– Criteria: Unit ready to produce electricity at end of each outage

Project Team

Owner: RCCMH

Engineer: WP

Constructor: Nooter

FGD OEM: MET

O&M Services: NAES

Project Organization Chart

Phased Approach Work Schedule

Developed execution plan during proposal– Reviewed contractor and owner safety plan, described construction

work plan, resource histogram, reporting and tracking requirements

All workers attended a Site safety orientation presentation Fire blankets and fire watch were critical for a rubber-lined vesselWorkers required to wear harnesses when in vessel for protection from falling Workers used the “Buddy System” to help insure a safe working environment Project risks reviewed and mitigation strategies implemented

Constructability

Components designed and fabricated to pass through access doors– Bottom absorber door - 30 inch X 54 inch– Hoisted to work level

ALRD Level 1 – 75’ ALRD Level 2 – 80’

Scaffolding installation critical– Structural integrity of spray headers as supports verified– Positioning precarious

Needed to protect rubber lining on pipe header, spray nozzles, and absorber vessel walls

Needed to be located to allow sections to be installed without interference

Constructability

ALRD Plates were delivered pre-drilled — Critical to be positioned correctly for holes to line upSection templates were provided to ensure proper fit– Constructed of stainless steel and weighed ~40 lbs– Used templates to make replicas of plywood that weighed ~4 lbsBrackets and plates designed to be modular for ease of handling and installationInnovative use of graphics to report progress daily

Constructability

Tower scaffolding was installed on top of the spray headers and the

attachment plate locations were laid out

Execution of Work

The rubber lining was removed

The shell was prepped for welding

Execution of Work

The bracket was made of CS base plate and shop welded to the alloy bracket for

easy field welding

All of the support brackets were installed and aligned

using the actual plates

Execution of Work

All welding was completed before any of the rubber lining

efforts were began

The ALRD support bracket shell and rubber lining was beveled to ensure proper lining profile

Execution of Work

All the lining efforts were completed before the plates

were installed

The plates were installed, bolting was selected as the preferred

method of attachment

Execution of Work

The plate was lined to seal it to the wall to ensure all the liquid running

down the wall could be re-entrained

The work area was cramped but all work

was performed without incident or

any lost time

Execution of Work

System operated to meet the 0.15 lbs SO2/MMBtu after May 1st

Performance Results

System operated to meet the 0.15 lbs SO2/MMBtu on 30 day rolling average

Performance Results

courtesy of EPA's Clean Air Markets Division

The upgrade, from proposal to installation, was accomplished in a 10 month period

2500+ man-hours of installation work without incident

Scheduled outages utilized for equipment installation

Capital Investment for upgrade was minimized

System was able to successfully achieve state-required emissions limit– Increased SO2 removal from 93% to 97% at 3.2% Sulfur coal

– Outlet Emission of 0.15 lbs SO2/MMBtu is achieved

– No noticeable increase in pressure drop– No change to any of the existing recycle pumps or spray headers

Conclusions

Contact Information:

Amy Evans | Marsulex Environmental Technologiesaevans@MET.net

717-274-7129

Dennis Del Vecchio | NACE CorporationDennis.delvecchio@blengland.com

609-390-5171