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Environmental Systems & Upgrades

B&W’s broad range of sustainable power generation experience and expertise in emissions control provides the insight necessary to evaluate, recommend and implement cost-effective solutions to improve system performance.

We work as a team with our customers to develop Net Present Value (NPV) calculations to analyze the profitability of proposed solutions to determine the best approach forward to support your emissions compliance programs.

As experts in this field, we recognize and take advantage of opportunities to apply proven technology to existing equipment that provides tangible benefits for our customers.

As a single-source supplier, B&W provides a complete package of integrated environmental upgrade and aftermarket services, including:

  • Engineering assessment of recurring issues
  • Upgrades for aging equipment
  • Replacement parts
  • Installation and construction services
  • Startup and commissioning
  • Performance testing and monitoring
  • Field engineering services
  • On-site inspections
  • On-site training programs

B&W supports environmental system upgrades, services and replacement parts for equipment originally supplied by us as well as other manufacturers.

Our experience includes:

Environmental System Upgrades

Environmental Systems


Electrostatic Precipitator Upgrades

Aging technology and lack of support from some original equipment manufacturers and aftermarket suppliers has resulted in lost productivity and reduced efficiency for many electrostatic precipitator (ESP) systems.

Electrostatic Precipitator Upgrades

ESP products and services provided by B&W are designed with one goal in mind—to help keep your ESP functioning at peak performance. Our vast worldwide industry experience, which includes technology formerly offered by Joy Western Precipitation, BHA, GE Energy and Rothemühle, enables us to provide integrated solutions to enhance equipment performance, regardless of original manufacturer. We provide engineered upgrades, quality components, services and construction to help keep your ESP running efficiently and effectively. Our combination of innovative, cost-effective products and services include:

  • Unitized and strip collecting plates
  • Wire, rigid frame and rigid discharge electrodes
  • Rapper and rapper components
  • Insulators
  • Access doors and door seals
  • Purge air systems
  • Single and 3-phase power supplies and automatic voltage controls
  • Rapper controls
  • Electrical performance enhancement hardware and software
  • 24/7 remote diagnostics
  • Upgrades, rebuilds, construction, re-powering and conversions
  • Field services
  • Training seminars
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Upgrades for Wet FGD Absorbers & Systems



Competitor wet FGD retrofitted with B&W's dual tray technology

  • Increased SO2 removal from 83 to 98% 

Full condition assessment of wet FGD system; upgraded absorber pumps and spray headers/nozzles; upgraded and replaced reagent preparation and dewatering equipment

  • Increased SO2 removal from 91 to 99%
  • Increased reliability
  • Reduced maintenance

Major upgrade of wet FGD system: conversion to forced oxidation; new absorber trays; new spray headers and nozzles; new mist eliminator blades and wash system; additional milling capacity; new hydroclones and belt filters

  • Increased SO2 removal from 85% to 95%
  • Production of saleable gypsum (reduced byproduct disposal costs)
  • Reduced maintenance
  • Reduced footprint

Performed upgrades to trays, mist eliminators and waterwash system on four wet FGD units

  • Increased reliability
  • Reduced maintenance

Converted a wet FGD to limestone reagent


  • Lowered system operating cost
  • Increased reliability
  • Reduced maintenance

Added spray dryer absorber module for increased load

  • Increased reliability
  • Reduced system pressure drop

Process tuning for a dry FGD system

  • Lowered lime consumption
  • Increased operating flexibility

ESP rebuild with a top rapped system

  • Increased reliability
  • Reduced maintenance

Dry sorbent injection system

  • Reduced SO3 emissions generated across SCR to eliminate blue plume
  • Reduced acid formation potential in ductwork and ESP

Niro Atomizer Oil Pump Babcock Wilcox

Niro Atomizer Oil Pump & Gear Unit Exchanges and Replacement Parts

B&W is the exclusive North American licensee of GEA Process Engineering A/S, for the GEA Niro spray dry absorber (SDA) process serving the air pollution control needs of the power, energy-from-waste and industrial sectors. This process is globally recognized as the spray dry flue gas desulfurization (FGD) technology of choice. The heart of this system is the GEA Niro rotary atomizer which is used to atomize a mixture of lime and recycle slurry into a fine spray. The GEA Niro rotary atomizer is a robust, heavy-duty design, utilizing specially selected abrasion resistant materials for reliable, safe and continuous operation between scheduled maintenance.

One call to B&W provides access to the largest North American inventory of original GEA Niro replacement parts. Our warehouse stocks all major components and replacement parts for the atomizer, including:

  • Gear boxes
  • Atomizer wheels
  • Oil coolers
  • Oil pumps
  • Lubrication system components
  • Spindles
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