Boiler MACT & Particulate Control System Study

Location: Louisiana, Mo.

Client: Hercules Inc.

Completion Date: 2004

Burns & McDonnell was hired by Hercules to identify and evaluate the impacts of the proposed Industrial Boiler Maximum Achievable Control Technology (MACT) rule on a coal-fired industrial boiler facility. The evaluation studied four compliance alternatives for three 140,000 pounds/hour coal-fired boilers and two steam turbines. These four alternatives included:

  1. Upgrading existing boilers with additional air pollution control equipment.
  2. Conversion of existing coal fired boilers to hybrid gas/coal burners.
  3. Installation of gas turbines and heat recovery steam generators (HRSG).
  4. Replacement of existing boilers with natural gas fired package boilers.

The study evaluated existing facility emissions, determined compliance requirements in light of the proposed Industrial Boiler MACT and other environmental regulations, and developed conceptual equipment arrangements for each of the alternatives. Analyses included operations and maintenance costs, capital costs, fuel costs, and electrical costs, all of which were used as inputs to pro forma economic evaluations of each alternative to determine the most viable options for Hercules. A sensitivity analyses was provided for multiple variables of each alternative.

The final deliverable included a detailed report with supporting documentation and basic general arrangement drawings for each alternative. The project and final deliverable met or exceeded Hercules’ expectations in terms of cost, quality and schedule, and has proven extremely useful in their corporate long-term planning process.


  • Review of coal analyses and development of design basis
  • Regulatory and compliance reviews
  • Alternatives evaluation
  • Feasibility studies
  • Cost estimates and economic analyses