Plant Design

When the Łagisza power plant began commercial operation in late June 2009, it marked the beginning of a new era in the evolution of circulating fluidized bed (CFB) technology. At the heart of this 460-MW plant is the world’s largest CFB boiler, which is also the world’s first once-through unit supercritical CFB boiler.

Reducing dust from coal conveyors has moved from a housekeeping chore to a safety challenge, especially with Powder River Basin coals. Here’s what you need to know about the latest coal-handling system design.

FirstEnergy has announced plans to repower two coal-fired units at the R.E. Burger plant to burn biomass. Conversion of the two units, expected to be completed by 2012, gets the utility off the hot seat with the EPA for alleged Clean Air Act violations.

Recent improvements in the performance of steam power plants have been achieved with advanced computerized controls. These new control schemes not only reduce fuel consumption and make the plant much more responsive, but they also can significantly decrease start-up commissioning time and cost.

The UK has all but doomed new coal-fired capacity by simultaneously setting binding carbon reduction goals and by requiring carbon capture and sequestration (CCS) of carbon emissions from new  mid-size coal-fired power plants. Existing plants will also be required to retrofit their plants when CCS technology is demonstrated, now estimated to happen by 2020.

Many coal-fired power stations built before 1980 were designed for handling relatively easy-handling lump coal. If your plant’s bins, bunkers, and silos aren’t up to dealing with today’s range of more variable coal properties, this case study shows one way to minimize coal flow problems.

The 200-MW Dallman Unit 4 under construction in Springfield, Ill., is expected to cost approximately 20% less to operate per megawatt-hour than the most efficient of the three existing Dallman units. A composite stack liner is one element enabling that cost savings.

The flue gas desulfurization process requires the use of aggressive liquids that significantly shorten the life of typical construction materials such as metals and concrete. That makes fiberglass-reinforced plastic (FRP) the material of choice for many components in a typical flue gas desulfurization (FGD) system.

Replacing existing, older-generation controlled-flow split-flame burners on Unit 1 at the Seminole Generating Station with Foster Wheeler’s new low-NO_x burners and overfire air additions reduced NO_x emissions. This case study provides all the details and post-installation test results.

Many automation engineers are coming face to face with real fieldbus applications for the first time. Fieldbus (the use of digital communications networks for distributed instrumentation and control) is a wonderful technology with many benefits, but fieldbus installation requires some additional considerations over and above normal 4-20 mA projects. In this article, I present some of those issues and show you how to deal with them.

Reducing NO_x, SO₂, and other air pollutants continues to be a challenge for the power generation industry. The technologies are well-understood, but the devil is always in the details, especially when a complex treatment system is retrofitted to an existing plant.

The most common method for reducing SO₂ from plant emissions is the conventional lime- and limestone-based flue gas desulfurization (FGD) system. Material-handling systems for limestone and gypsum present specific challenges and opportunities that differ from those of coal-handling systems. This article looks at factors to consider  before and during the design of a new material-handling system. The choices you make about these many variables will determine the cost and longevity of your system.

In early June, New York Gov. David Paterson proclaimed that his state would commit $6 million to buttress a carbon capture and sequestration (CCS) viability study for the development of a new 50-MW clean coal plant in Jamestown, in western New York. The circulating fluidized-bed (CFB) project, which would use pure oxygen to combust coal and subsequently capture and sequester 90% of emitted carbon dioxide (CO₂), would be “the first of its kind in the world” and could potentially enable New York firms to launch exports of the technology worldwide, Paterson promised.

In recent years, Sargent & Lundy has evaluated many potential sites for new coal-fueled generation. Some of the sites studied were lands adjacent to existing power plants (brownfield sites); others were undeveloped greenfield sites. The numerous technical, environmental, economic, and regulatory issues that bear on power plant siting generally apply to both brownfield and greenfield […]

Production from Wyoming Powder River Basin (PRB) coal mines ended last year with a increase of only about 1.1%, reflecting a record 451.3 million tons, according to the Department of Energy’s Energy Information Administration. Production of PRB coal spiked with a record 10% growth in 2006 following two derailments on the PRB’s main triple-track line […]

The FutureGen Industrial Alliance Inc. selected Mattoon, Ill., as the site of the $1.8 billion FutureGen project just before Christmas, but the plant may never move off the drawing board.. FutureGen, the proposed prototype of a near-zero-emissions coal plant, is to demonstrate advanced technologies for coal gasification, electricity production, emissions control, CO 2 capture and […]

Integrated gasification combined-cycle (IGCC) technology, a process of gasifying coal that allows the capture of carbon dioxide emissions, has tremendous potential for meeting future baseload generation demand. Though it is one of the leading alternatives for producing clean power from coal, IGCC faces a precarious future due to rising capital costs and regulatory uncertainty. We’re […]

Burning biomass or nonrecyclable commercial, municipal, or industrial waste along with coal represents one of the nearest-term and lowest-cost options for reducing carbon dioxide (CO 2) emissions from existing utility power plants. At more than 150 plants worldwide, doing so has produced lower CO 2 emissions than burning coal alone. Indeed, with the number of […]

Like many older coal-fired plants, Westar Energy’s Jeffrey Energy Center (JEC) was built with traditional, pneumatic flyash-handling and removal systems. Such systems collect flyash in hoppers attached to the bottom of a unit’s electrostatic precipitator (ESP) and/or baghouse. Periodically, the hoppers are emptied into tanks and the flyash is conveyed away for disposal or beneficiation. […]

All conveyor systems are at risk of fire caused by the ignition of transported materials or equipment failure. But the propensity of Powder River Basin (PRB) coal to self-ignite introduces an exceptional hazard requiring special fire prevention and automatic detection and suppression efforts. To that end, this article discusses the technologies of linear heat detection […]

This August, Peabody Energy’s 1,600-MW Prairie State Energy Campus project in Illinois won a major federal appeals court decision, removing the last obstacle to groundbreaking. The six-year regulatory review process ended with an unsuccessful Sierra Club challenge to the $2.9 billion project’s air permit. The decision is sure to reverberate across the nation, and I […]

Lansing Board of Water & Light (LBW&L), which has generated electricity since 1892 and steam since 1919 in mid-Michigan, primarily serves the city of Lansing’s business district and all state government buildings in the downtown area. But one of the municipal utility’s plants, Moores Park, has an additional and very important steam customer: General Motors’ […]

Since ratification of the Clean Air Act (CAA) in 1970, U.S. utilities have made steady efforts to install pollution control equipment to curb power plant stack emissions. The CAA Amendments of 1990 raised concerns at the time about the industry’s ability to install a large number of flue gas desulfurization (FGD) systems, or scrubbers, in […]

This July, an underground steam pipe near Manhattan’s Grand Central Terminal ruptured and spewed a scalding brown geyser of steam and debris higher than the nearby 77-story Chrysler Building. The blast, which injured 30 people, created a 40-foot crater at street level that swallowed a tow truck. A similar explosion in 1989 killed three people. […]

Synfuels’ political bubble has burst in Washington, but the market may step in where Congress fears to tread. When coal industry interests, in the form of the CTL Coalition, got a bill with strong federal support for coal-to-liquids technology before the Senate this spring, it appeared that the political skids were greased for some kind […]

The U.S. Department of Energy (DOE) and Great River Energy are testing a new coal-drying technology that could dramatically reduce the emissions of lignite-burning power plants. The project was selected for funding during Round I of the DOE’s Clean Coal Power Initiative (CCPI), a series of competitions to demonstrate a range of promising clean-coal technologies. […]

Former Illinois Senator Everett Dirksen once observed, "A billion here and a billion there, and pretty soon you’re talking real money." The same can be said about skyrocketing estimated costs of integrated gasification combined-cycle (IGCC) plants as their designs are fleshed out. The higher price tags shouldn’t be a surprise — the more you learn […]

Lawrence Energy Center (LEC) proudly hosted about 60 representatives of the Powder River Basin Coal Users’ Group (PRBCUG) at its July 24th open house, luncheon, and plant tour. LEC was named the PRBCUG’s 2007 Plant of the Year at this year’s ELECTRIC POWER Conference and Exhibition in Chicago, May 1 – 3. Traditionally, the winning […]

The 1990 amendments to the Clean Air Act require coal-fired power plants to reduce their emissions of the pollutant SO2. To do so, many have switched to, or are considering switching to, Powder River Basin (PRB) coal. Unfortunately, PRB coal has a tendency to leave excessive and tenacious deposits on boiler heat-exchange surfaces. Complicating the problem, the distribution of the deposits is far from uniform.

It’s déjà synfuels all over again. With crude oil prices seemingly interminably pegged at over $60 a barrel, the old, beguiling notion of turning coal into liquid fuel — a task accomplished by the Nazis in the 1940s and the South Africans in the 1970s and 1980s — is once again front-page political news in […]

Money is always spent with the best intentions. We look for the best deal, often identifying it by the lowest price. Sometimes, our choice works out and we save money and get a great product. When it doesn’t work out, however, we find ourselves spending more and more money to repair or replace our "great […]