Boiler MACT-Related & Particulate Control Study

Location: Indianapolis

Client: Citizens Thermal Energy

Completion Date: 2004

Citizens Thermal Energy (CTE) chose Burns & McDonnell to assist in developing alternative strategies and capital cost estimates for the retrofit of air pollution control equipment at the Perry K Steam Plant in Indianapolis. CTE may be required to retrofit air pollution control equipment to the plant to comply with the emission limits of the Industrial Boiler Maximum Achievable Control Technology (MACT) Rule.

Through previous investigations, CTE had tentatively determined that a fabric filter would be required to treat flue gases from boilers 12, 15 and 16. Furthermore, CTE had contemplated retrofitting a fabric filter inside the casing of the existing common electrostatic precipitator (ESP) for boilers 15 and 16. This retrofit fabric filter would treat the exhaust gases from boilers 15 and 16 as well as the flue gas exiting the boiler 12 ESP, which would remain in service. During the course of the evaluation and cost estimates, Burns & McDonnell worked closely with CTE to develop innovative strategies, equipment arrangements, constructability reviews and cost-effective approaches for this landlocked facility, in addition to the originally conceived plans.

Burns & McDonnell’s scope of work included:

  • Site visits: Several site visits and walkdowns were conducted to assess the feasibility of a fabric filter retrofit and balance of plant issues, such as ductwork routing, draft system modifications, etc. Plant data was gathered including operating data (coal data, boiler heat input, boiler excess air, flue gas temperatures), drawings and previous investigational studies.
  • Establishment of design basis: Burns & McDonnell reviewed information provided by CTE to develop a design basis that established the flue gas flow rates, uncontrolled pollutant concentrations and outlet emissions.
  • Review and recommend compliance strategy: CTE and Burns & McDonnell reviewed the potential compliance strategies and corresponding cost estimates and determining recommended approach.
  • Develop cost estimates: Cost estimates were developed though Burns & McDonnell’s Construction/Design-Build group based on a “bottom-up” type estimate. Burns & McDonnell also utilized budgetary pricing for the major air pollution control equipment.
  • Review of coal analyses and development of design basis
  • Regulatory review
  • Alternatives evaluation
  • Cost estimating