Comanche Station Units 1, 2 and 3
Dry Flue Gas Desulfurization Systems

Babcock & Wilcox (B&W) dry flue gas desulfurization (FGD) 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 spray dryer absorber (SDA) process. The GEA Niro SDA is globally recognized by the power generation industry as the dry FGD 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, integral mercury emissions reduction, low capital cost, high system availability, and low operation and maintenance costs.

Boiler/Plant Information

  • Unit 1: 360 MW gross
    Unit 2: 365 MW gross
    Unit 3: 830 MW gross
  • Boiler type: Pulverized coal-fired
  • Design fuel: Powder River Basin (PRB) subbituminous

Project Summary

  • Supply and installation of a complete dry flue gas desulfurization system, including reagent preparation and recycle, for Units 1, 2 and 3; pulse jet fabric filter for Unit 3.
  • Type: Lime spray dryer absorber (SDA) system
  • Startup dates: 2008 (Units 1 and 2) and 2009 (Unit 3)

Comanche Station Units
The unique flue gas dispersion system, coupled with the reliable atomizer, allows optimal gas and reagent mixing for high SO2 removal efficiencies.

Unit 3 SDAs and pulse jet fabric filter

Unit 3 SDAs and pulse jet fabric filter.

Comanche BWCC
BWCC, a B&W subsidiary, provided construction services for all B&W supplied air quality control system equipment and structural steel.

B&W Scope

  • Spray dry absorber systems:
    - Unit 1 – 2 SDAs
    - Unit 2 – 2 SDAs
    - Unit 3 – 3 SDAs
  • Recycle ash systems
  • Lime rail car unloading systems (common for all units)
  • Lime slaking systems (common for all units)
  • 2 x 10 compartment pulse jet fabric filter for Unit 3
  • Mercury removal system
  • Piping, supports, elevators and freeze protection systems
  • 2 x 12,500 hp induced draft axial fans for Unit 3
  • Structural steel, flues, dampers, and enclosures
  • Construction of all B&W supplied equipment and structural steel, through Babcock & Wilcox Construction Co., Inc. (BWCC), a B&W subsidiary
  • Commissioning

The project met every engineering, fabrication and construction schedule milestone. The commissioned units are currently meeting all performance guarantees.

New Build

B&W Projects New Build
We consistently demonstrate the ability to successfully execute innovative solutions for our customers, from new equipment to large, complex full-scope engineering and construction projects.

Upgrades / Retrofits

Upgrades and Retrofits by B&W
Modifying, improving and maintaining existing equipment are vital considerations for the long-term viability and profitability of all operations.

Parts / Services

Babcock & Wilcox Parts and Service Support
An extensive network of worldwide regional service centers, field service engineers and technical support personnel are available to provide the customized service and aftermarket solutions for your requirements.