Success Stories

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Hatfield’s Ferry Station Case Study

Hatfields Main Image Babcock Wilcox

Hatfield’s Ferry Station Units 1, 2 and 3

FirstEnergy Generation Corp.

Masontown, Pennsylvania

Plant Owner

FirstEnergy Generation Corp. a subsidiary of FirstEnergy Corp.

Plant Name

Hatfield’s Ferry Station Units 1, 2 and 3


Masontown, Pennsylvania

Contract Order: 2006

Commercial Operation: 2009

The wet flue gas desulfurization (FGD) system from Babcock & Wilcox (B&W) features a combination of design components to provide a high level of reliability and removal efficiencies. These include B&W's signature dual tray tower design that provides excellent gas-to-liquid contact and uniform flow distribution through the absorber spray zones; its patented inlet awning; interspatial headers to reduce absorber height, pump power requirements, and internal support costs; forced oxidation system; and advanced mist eliminators.

Boiler/Plant Information

Project Summary

  • Engineering, procurement and construction of a wet FGD system
  • System designed to remove 98% of the entering sulfur dioxide (SO2)
  • Type: Limestone forced oxidation with gypsum byproduct
  • Project awarded: April 2006
  • Construction plan included on-site scrubber module fabrication area
  • Operation dates:June 2009(Unit 1); October 2009(Units 2 and 3)

Hatfield's Construction

B&W Scope

  • Three wet FGD absorbers (one per boiler)
  • Three limestone milling systems (one per boiler)
  • Gypsum dewatering system including four horizontal table filters (three operating, one spare)
  • Buildings and structural steel
  • Construction of B&W supplied equipment and steel provided by Babcock & Wilcox Construction Co., Inc.


  • Achieved mechanical and substantial completion milestones ahead of schedule
  • All commissioned units have met performance guarantees

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Hatfield's Silos

Construction Plan Constraints

The construction plan included an on-site scrubber module fabrication area that produced absorber modules for both the Fort Martin and Hatfield’s Ferry sites. This plan optimized modularization opportunities because off-site modularization was not feasible due to access constraints created by locks on the adjacent Monongahela River.

Hatfield's RoadHatfield's River