Crystal River Units 4 & 5 AQCS Retrofit

Crystal River Units 4 & 5 AQCS Retrofit

Location: Crystal River, Fla.

Client: Progress Energy

Completion Date: December 2010

Burns & McDonnell, in a joint venture called Environmental Partners Crystal River LLC (EPCR) that includes Zachry Construction Co. and Utility Engineering, is the engineer-procure-construct (EPC) contractor for a turnkey emission control project at Progress Energy's Crystal River Units 4 and 5, including complete engineering, procurement, construction, startup and commissioning.

  • Preliminary engineering
  • Detailed engineering
  • Procurement
  • Construction
  • Construction management
  • Startup and commissioning

The Crystal River project includes the refurbishment of an existing hot-side electrostatic precipitator (ESP) by the owner, refurbishment of air heaters, replacement of existing burners with low NOx burners (LNB), new selective catalytic reduction (SCR) and new wet flue gas desulfurization (FGD) for 2 x 750 MW pulverized coal (PC) units. The work includes all necessary design, demolition, procurement, construction, erection, controls and auxiliary support equipment for a complete system.

EPCR is to retrofit a new wet lime FGD system. The wet FGD is to be capable of 97 percent SO2 removal and 99.5 percent reliability. The wet FGD system retrofit also includes new dual flue chimney, limestone grinding and gypsum dewatering facility, gypsum and limestone material handling, new ID fans and ductwork. The new SCR retrofit includes a new urea to ammonia conversion system, injection grid, catalyst and ancilliaries. The low NOx burner and SCR system shall achieve an SCR outlet NOx emission of 0.041 pounds/MMBtu heat input.

Burns & McDonnell will perform civil, process, mechanical, electrical, structural and foundation design as well as instrumentation and controls. The controls engineering will consist of integrating a new distributed control system (DCS) for the FGD, SCR and new balance of plant equipment with the existing plant DCS.

This project will require significant coordination and effort among the EPC joint venture partners and with owner Progress Energy to accommodate substantial tie-in work during scheduled outages. This project is a fast-paced, highly coordinated effort that requires teamwork, persistence and a willingness to work together with Progress Energy to ultimately make them successful and achieve a high level of environmental stewardship and a value to the customers Progress Energy serves.

  • Selective catalytic reduction (SCR)
  • Wet flue gas desulfurization (FGD)
  • Low NOx burners
  • Air heater upgrades
  • Limestone grinding and handling
  • Gypsum dewatering and handling