a McDermott company

Wet Flue Gas

Desulfurization
(FGD) Systems

Advanced technology for reliability

and maximum SO2 removal

B&W Wet FGD Systems Flexibility of design

and advanced features to meet customer needs

When Performance
Counts

B&W FGD systems are

backed by an experienced
staff of design engineers,
a network of field service
engineers, and extensive
research and development.

Babcock & Wilcox (B&W)

wet FGD systems have
always achieved design
guarantees. Since 1971, our
FGD systems have operated
efficiently, economically and
reliably. Year after year, all
systems have maintained
compliance with EPA New
Source Performance
Standards.

Retrofit Experience
B&W is equally skilled
designing FGD systems
for new plants and retrofit
applications. More than
50 percent of our FGD
experience has been the
retrofit of existing power
plants. In many instances,
scrubbers have been installed
in extremely tight locations
(see picture of Cinergys
Gibson Unit 4 on page 3).

Scope of Supply
B&W is a full-scope supplier.
In addition to flue gas
absorber modules, we have
supplied reagent preparation
systems, dewatering systems
and other system equipment
comprising a total turnkey
package. In addition,
we provide complete
construction services.

can be converted to calcium

sulfate through forced
oxidation to produce a
marketable, wallboard grade
gypsum. B&W first tested
in-situ forced oxidation in
1983, and now has more
than 18,000 MW of commercial units successfully
operating with this system.

Choice of Reagents
B&W has designed FGD
systems using a variety of
reagents. Based on installed
megawatt capacity, most
of our experience is with
limestone. Equally
successful designs have
utilized lime and sodium
reagents.

Oxidation Experience

Additionally, B&W has

improved the performance
of more than 5,000 MW
of competitors equipment
by replacing the original

Calcium sulfite, the predominant natural end-product

of a high-sulfur FGD system,

B&Ws FGD systems

have consistently met
and exceeded performance guarantees.

absorber internals with

B&Ws patented tray design.
Enhancements include
improved SO2 removal
performance, reduced
absorber pump power consumption and maintenance
costs, and the elimination
of costly additives.

Advanced Features
B&W continues to optimize
its FGD systems through
the use of innovative refinements to the technology.
As an indication of our efforts
to improve our designs, B&W
currently holds more than
40 patents involving wet
FGD technology.

Kentucky Utilities, Ghent Unit 1

Ghent, Kentucky, U.S.A.

American Electric Power, Gavin Units 1 & 2

Cheshire, Ohio, U.S.A.
Nominal Boiler Capability
Nominal Scrubber Capacity (ACFM, per unit)
Inlet SO 2 Concentration (ppm)
Percent SO 2 Removal
Commercial Operation
Fuel
Reagent
Oxidation Method

Nominal Boiler Capability

2 x 1300 MW

Nominal Scrubber Capacity (ACFM)

4,900,000

Nominal Scrubber Capacity (ACFM)

Inlet SO 2 Concentration (ppm)
Percent SO 2 Removal
Commercial Operation
Fuel
Reagent
Oxidation Method

1,900,000

Inlet SO 2 Concentration (ppm)

3,100

Percent SO 2 Removal

95
3/95, 5/95
Coal

2,487
90 (95 with acid addition)

Commercial Operation

1/95

Fuel

Coal

Reagent

Thiosorbic Lime

Oxidation Method

Natural

Limestone
Forced

New Brunswick Power, Dalhousie Units 1 & 2

Dalhousie, New Brunswick, Canada

Cinergy, Gibson Unit 4

Princeton, Indiana, U.S.A.
Nominal Boiler Capability

500 MW

Nominal Boiler Capability (combined)

668 MW

Nominal Scrubber Capacity (ACFM, per unit)

2,282,000

Inlet SO 2 Concentration (ppm)

2,600

Percent SO 2 Removal

92

Commercial Operation

12/94

Fuel

Coal

Reagent

Limestone

Oxidation Method

Inhibited

31

315 MW
1,078,400
2,300
90
12/94
Orimulsion
Limestone
Forced

Taiwan Power Company, Taichung Units 5-8

Taiwan
Nominal Boiler Capability

Public Service Co. of New Mexico, San Juan Units 1-4

Waterflow, New Mexico, U.S.A.
Units 1-2
Units 3-4
Nominal Boiler Capability
2 x 350 MW 2 x 550 MW

4 x 550 MW

Nominal Scrubber Capacity (ACFM, per unit)

Inlet SO 2 Concentration (ppm)

1,700,000

Nominal Scrubber Capacity (ACFM, per unit) 1,848,000

1,100

Percent SO 2 Removal

Inlet SO 2 Concentration (ppm)

92

Commercial Operation

Percent SO 2 Removal

6/98, 12/98, 3/99, 7/99

Fuel

Commercial Operation

Coal

Reagent

Fuel

Limestone

Oxidation Method

Reagent

Forced

Oxidation Method

Korea Electric Power Company, Taean Units 1-4, Hadong Units 1-6
Korea

TEAS, Kemerkoy Units 1-3

Turkey

Nominal Boiler Capability

Nominal Boiler Capability

10 x 500 MW

Nominal Scrubber Capacity (ACFM, per unit)

Inlet SO 2 Concentration (ppm)
Percent SO 2 Removal
Commercial Operation
Fuel
Reagent
Oxidation Method

1,385,000

Nominal Scrubber Capacity (ACFM, per unit)

645

Inlet SO 2 Concentration (ppm)

90

Percent SO 2 Removal

6/98, 8/98, 10/98, 12/98, 9/99, 3/00

Commercial Operation

Coal

Fuel

Limestone

Reagent

Forced

Oxidation Method

2,560,000

726

797

90

90
3/98 - 2/99
Coal
Limestone
Forced

3 x 210 MW
1,122,000
4,650
95
6/01
Lignite
Limestone
Forced

Through extensive
research and development, B&W continues
to improve upon its
FGD technology.

The B&W Wet FGD System with Single Loop

Absorber Spray Tower
Tower Design
B&Ws absorber module
is a counter-current design.
The slurry is sprayed
downward from a series
of headers and nozzles
and scrubs the flue gas as
it moves upward through
the tower. Continuous pH
monitoring is used to
control the addition of
fresh reagent. Density is
also monitored continuously
to control the addition of
make-up water to compensate
for evaporative losses.

Absorption Patented
Tray System

distribute the liquor. As

determined by both physical
and computer modeling,
the gas-side pressure drop
induced by the slurry sprays
is not sufficient by itself to
adequately distribute the
flue gas. Uniform gas distribution in a B&W spray
tower is achieved with a
patented perforated plate
or tray. Maintaining equal
distribution becomes more
critical in larger diameter
spray towers. Without a tray,
some zones of the absorber
have inconsistent gas distribution, which results in
zones of both inadequate
and excess reactant. With

The gas rises through the

B&W patented gas distribution tray, contacting a froth
of slurry. The uniform
distribution of flue gas
across the tower results
in the most efficient contact
of gas and reagent through
the multilevel spray zone.
The slurry and flue gas
must be equally distributed
across the absorber towers
cross section for optimum
SO2 removal. Extensive
spray header and nozzle
systems are used to evenly

the patented tray, flue gas

is redistributed to flow
uniformly up the spray tower
for the most efficient contact
with the recirculated slurry.
The tray is rugged, made
from an alloy steel. In
addition to optimum SO2
removal, inherent in the
design is a self-cleaning,
violent frothing action on
the tray that enhances
scale-free operation. The
tray also is used as a convenient inspection platform
for the spray nozzles.

Moisture Separator
Gas passing upward through
the spray tower will carry
droplets with it. Efficient
droplet separation is essential
to prevent slurry carryover
and deposition in the flue
downstream of the module.
In the B&W scrubber module, moisture is removed by
two levels of chevronshaped moisture separators
in a vertical or horizontal
gas flow orientation.

Tank Agitation
The slurry in the recirculation tank is agitated to keep
the solids in suspension.
Multiple side-entering
agitators on the recirculation tank provide uniform
mixing of the slurry.

B&Ws patented gas

distribution tray and
two levels of patented
interspatial spray
headers ensure uniform
gas distribution resulting
in optimum SO2 removal.

Full-Scope Capabilities
Modularization
B&W designs its scrubber
systems with modularization
in mind. For example, all
components for the 1300 MW
FGD system for the jointly
owned AEP/Cinergy/DP&L
Zimmer Generating Station
and AEPs 2600 MW Gavin
Station were manufactured
off site due to limited
laydown area. This technique
significantly reduced both
the project schedule and

construction costs and

represented an important
advancement in manufacturing and construction
technology.

wet scrubber retrofit project,

B&W and Public Service
Co. of New Mexico entered
into a strategic alliance
that allowed both companies
to share ideas, solutions,
and most importantly, the
cost savings that resulted
because of the arrangement.
Effective communication
and trust helped make this
project a success. A similar
strategic alliance was also
used in a successful dry
scrubber project.

Project
Management/Retrofit
Many times, a project calls
for new ways of thinking.
B&Ws innovation goes
beyond traditional project
management and vendor/
supplier relationships. In a

Modularization
significantly reduces
both project span and
construction costs.

Turnkey Projects
B&W provides total-scope
services, such as project
engineering, fabrication
and installation of complete
environmental emissions
control equipment. Our
environmental equipment
capabilities include baghouses, precipitators and
selective catalytic and
non-catalytic reduction
systems for NOx control.

B&W supplied a wet

FGD system, precipitator
and boiler for this plant
in central Florida. Our
outstanding cooperation
led to the customer
awarding us a key
to the city (first ever
to a supplier).

B&Ws scrubber retrofit

project for Public Service
Co. of New Mexicos San
Juan Station was performed through a strategic
alliance arrangement,
resulting in significant
cost and schedule savings.

a McDermott company

While others may use the Babcock name, we are

the original Babcock & Wilcox with more than
130 years of experience in engineering, constructing
and servicing steam generating systems. Insist on
us by name.
For more information, or a complete listing of
our sales and service offices worldwide, call
1- 800 - BABCOCK (222-2625) in North America.
Outside North America, call (330) 753- 4511 or
fax (330) 860 -1886 (Barberton, Ohio, USA). Or
access our Web site at www.babcock.com.
Canada:
Cambridge, Ontario
Edmonton, Alberta
Montreal, Quebec
Saint John, New Brunswick
Vancouver (Richmond), British Columbia
Denmark: Esbjerg
India: Pune
Indonesia: Jakarta
Peoples Republic of China: Beijing
Singapore: Singapore
United States of America:
Atlanta, Georgia
Barberton, Ohio
Charlotte, North Carolina
Chicago (Downers Grove), Illinois
Cincinnati, Ohio
Dallas, Texas
Denver (Sheridan), Colorado
Fairfield, New Jersey
Houston, Texas
Kansas City, Missouri
Mt. Holly, New Jersey
San Francisco (Napa), California
St. Petersburg, Florida

Helping our customers

improve the environment
Working with our customers, B&W provides worldwide leadership in environmental products and services by applying
the best technology through innovation, responsiveness and
employee commitment.

A barge carrying Babcock & Wilcox

scrubber modules passes the Zimmer
Station, jointly owned by AEP, Cinergy
and Dayton Power & Light, on its way
to AEPs Gavin Station. The success of
the Zimmer scrubber is evidenced by
repeat business for B&W at AEPs
2 x 1300 MW Gavin Station.

Powering the World Through

Teamwork and Innovation

The information contained herein is provided for general information purposes only and is not
intended or to be construed as a warranty, an offer, or any representation of contractual or other
legal responsibility.
Powering the World Through Teamwork and Innovation is a trademark of
The Babcock & Wilcox Company.
Thiosorbic is a trademark of Dravo Lime Corporation.
2001 The Babcock & Wilcox Company. All rights reserved.
Orimulsion is a trademark of Bitor America Corporation.

E101-3167 5MD1D