POWER August 2010 - 37

2010 MARMADUKE AWARD
2. Erector set. This photo shows the preassembled
reheater module being lifted into
place. In the background, the cyclones are already
in place. The cyclones were fabricated
in two vertical halves, lifted into place, and
then welded. Courtesy: Cleco Power
3. The art of burning petcoke. Petcoke is crushed to about ΒΌ-inch diameter, mixed with
crushed limestone, and gravimetrically metered as it is injected into the circulating fluidized bed (CFB)
combustor. As the solid mixture rises, it ignites and begins a controlled " slow burn " based on the
quantity of air injected. The slow burn process maintains temperatures below 1,600F to minimize
NOx formation, and the limestone removes about 90% of the SO2. The fuel particles become lighter
as they burn, move higher in the combustor, and constantly move in a fluid-like motion. The cyclones
remove the solid particles from the gas stream and reinject them back into the combustor and provide
additional residence time to complete combustion. Aqueous ammonia is injected at the cyclone inlet
to further reduce NOx produced in the furnace. Water flows through the cyclone and into the drum.
Saturated steam leaving the drum then flows across the roof tubes, through the cyclone outlet duct
and into the convection pass cage, into the primary superheater, then into the intermediate and finishing
superheaters. The intermediate and finishing superheater are pendant sections or wing walls in
the furnace. After passing through the reheater/primary superheater, economizer, and tri-sector air
heater, the flue gas enters an air quality control system. There it travels downward through a polishing
dry scrubber that reinjects a fly ash that is still rich in calcium oxide (CaO) with spraywater to absorb
additional SO2. Following the scrubber, the flue gas passes through a baghouse containing fabric filters
to further clean the gas before it is sent up the stack. Solid material, consisting primarily of ash and
calcium sulfate (CaSO4), is removed from the bottom of the combustor and the baghouse and sent to
by-product storage. Source: Cleco Power/Foster Wheeler/DOE
Air
High-pressure steam
Lower pressure steam
Water
Particulate
Lime slurry
Petroleum
coke
slam-dunk, Fontenot says. Although petcoke
is the primary fuel today, the plant was
designed to also burn Illinois #6 coal, Powder
River Basin coal, and lignite. The CFB
boilers can also burn a variety of biomass
fuels should renewable portfolio standards
require doing so, or if biomass opportunity
fuels become cost effective in the future.
Cleco has studied using woody biomass as a
potential fuel, because the project is located
in a timber-rich area.
Meeting Regulatory Rules
There is good news for petcoke users, at
least for the short term: The Environmental
Protection Agency (EPA) does not consider
petcoke to be a " fossil fuel " under its
emissions standards for new power plants,
but rather a by-product of the refining process,
a " waste " that also happens to be a
good fuel. Plants that can use petcoke have
a substantial advantage, as noted by the
short period of time required for permitting
Madison Unit 3 (see Table 1) over those
attempting to gather permits for a new,
conventional coal-fired plant. For petcoke,
emissions limits are based on best available
control technology (BACT) for the facility
to satisfy the EPA's stringent air quality
regulations.
To adhere to Cleco's fuel flexibility design
requirement and meet BACT requirements,
Cleco selected two 50%-sized CFB
boilers supplied by Foster Wheeler Corp.
to burn the petcoke in an environmentally
acceptable manner (Figure 2). As part of
August 2010 | POWER
Limestone
Secondary
air
Air
Polishing
scrubber
Reheat
Air
Bottom
ash
To by-product storage
the CFB design, limestone is mixed with
the petcoke in the CFB bed in order to promote
complete combustion and " scrub " the
petcoke of sulfur. Because the firing temperature
in the CFB is kept below 1,600F,
thermal NOx
does not form. Table 2 summarizes
the key performance data for Madison
Unit 3.
Beyond the CFB, Foster Wheeler provided
additional flue gas treatment, including a
selective noncatalytic reduction system to reduce
NOx
to complete the SOx
emissions and a dry lime scrubber
removal process. Provisions
for activated carbon injection for mercury
control are included in the plant design,
should the regulatory requirements for controlling
mercury from petcoke-fired plants
change. As a final treatment step, a pulse jet
fabric filter polishes the exhaust gases, removing
at least 99.9% of the remaining fine
particulates (Figure 3).
Stay-at-Home Dollars
Madison, in comments made last August,
noted the significant investment that Cleco
www.powermag.com
Generator
Steam turbine
is making in Louisiana by building Madison
Unit 3. He estimated Cleco would spend
$482,000,000 on materials, equipment,
fuel, and labor in Louisiana by the time the
project was completed. In addition, Cleco
has selected a locally available fuel and will
increase business activity in the region by
spending $43 million on materials, labor,
fuel, and maintenance each year to operate
the unit. Locally, the project has created
80 permanent jobs. " We're investing in our
state by using a byproduct of Louisiana for
fuel and Louisiana's waterways to transport
the fuel. We hired a Louisiana company to
build Rodemacher 3, " he said.
The engineering, procurement, and construction
(EPC) contract was awarded to
The Shaw Group (Shaw), located in Baton
Rouge, after Cleco shopped the project to
four qualified EPC contractors. As part of
that contract, Shaw was responsible for
the supply and erection of the boiler island
(CFB boilers and air quality control
systems), turbine island (steam turbine
and auxiliaries), material-handling sys37
Air
exchanger
Steam
Condenser
To
by-prodect storage
Steam
Ammonia
injection
fluidized-bed boiler
Circulating
Cyclone
Feedwater
Economizer
Heated
air to
boiler
Air preheater
Dry
lime Particulate
control
device
Stack
http://www.powermag.com

POWER August 2010

Table of Contents for the Digital Edition of POWER August 2010

Contents
POWER August 2010 - Cover1
POWER August 2010 - Cover2
POWER August 2010 - Contents
POWER August 2010 - 2
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