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Monroe Units 1, 2, 3 and 4 Case Study

Detroit Edison Monroe Units 1 4 1 Babcock Wilcox

Monroe Units 1, 2, 3 and 4 Wet Flue Gas Desulfurization System

Detroit Edison

Monroe, Michigan

Contract Order

Units 3 & 4: 2006

Units 1 & 2: 2010

Commercial Operation

Units 3 & 4: 2009

Unit 1: 2013 Unit 2: 2014

Overview

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 tray tower design that provides excellent gas-to-liquid contact and uniform flow distribution through the absorber spray zones; its patented inlet awning; interspatial spray headers to reduce absorber height, pump power requirements, and internal support costs; forced oxidation system; and advanced mist eliminators.

Boiler/Plant Information

  • (PRB)/bituminous coal blend
  • Design fuel: Powder River Basin
  • Boiler type: Pulverized coal
  • 4 x 825 MW (3,300 MW total)

Project Summary

B&W provided engineering, procurement and construction of the wet FGD system. The system is designed to remove 97% of the entering sulfur dioxide (SO2) without organic acid addition, at an optimal combination of reduced absorber liquor recirculation (L/G) versus tray pressure drop. The system utilizes limestone reagent with forced oxidation to a gypsum byproduct. There is one absorber per unit.

 

B&W Scope

  • Four (4) wet FGD absorbers (1 per boiler), concrete tower with Stebbins tile construction and 2205 internals
  • Three (3) limestone milling systems (2 operating, 1 spare) Gypsum dewatering system that includes three (3) horizontal
  • table filters (2 operating, 1 spare) Six (6) oxidation air blowers (2 operating, 1 spare for each set of 2 absorbers)
  • Construction of B&W supplied equipment by Babcock & Wilcox Construction Co., Inc. (BWCC), a subsidiary of B&W

Schedule

  • Units 3 & 4 – The contract for units 3 & 4 was released in April 2006 with startup in June 2009 (Unit 4) and November 2009 (Unit 3)
  • Units 1 & 2 – Units 1 & 2 were awarded in March 2010 with operation scheduled for December 2013 (Unit 1) and May 2014 (Unit 2)

BWCC Construction Services

Detroit Edison Monroe Construction

BWCC provided construction services for all B&W supplied wet FGD system equipment at the Monroe power plant.

Results

  • Both commissioned units (Units 3 and 4) have met performance guarantees
  • Achieved mechanical and substantial completion on schedule

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Detroit Edison Monroe Computer Generated 3D

Computer generated three-dimensional projection of absorber modules at Monroe.