AECOM has been an FGD upgrade industry leader since the early 1970s, working with utilities to improve the operation and performance of their FGD systems.

As the power industry faces the challenge of increasingly stringent environmental regulations, flue gas desulfurization (FGD) systems must operate at peak efficiency and reliability, and must provide maximum and sustainable performance to meet current and future emissions requirements. AECOM has upgraded more than 52,000 MW of generating capacity in the U.S. alone. Because of this experience, we understand how to upgrade an older FGD system and improve its performance and reliability despite the design and operation limitations inherent in that system.

Examples of Project Successes
Scope Results

FGD performance upgrade

Conversion to forced oxidation

New dewatering system

 

SO2 removal increased from upper 80% to 97%

Production of high-quality gypsum byproduct

Single hollow cone spray nozzles replaced with double hollow cone (TwinAbsorb) nozzles

 

 

 

SO2 removal increased from 91% to over 98%

Elimination of need for performance additive

Ability to burn a higher sulfur fuel

Absorber upgrade

New mist eliminators

Conversion to forced oxidation

 

SO2 removal increased from 89% to over 98%

Production of high-quality gypsum byproduct

System reliability and operation improved

Absorber upgrade with new spray headers, trays, liquid distribution rings, recycle pumps, and mist eliminators

 

SO2 removal increased from upper 80% to 99%

Absorber upgrade with new spray headers, trays, and mist eliminators

Conversion to forced oxidation

New reagent preparation, dewatering and wastewater treatment systems

 

SO2 removal increased to over 98%

Production of high-quality gypsum byproduct

System reliability and operation improved

Wet FGD Upgrade Control Technologies

Through cost-effective upgrades, the performance and reliability of an older FGD system can be improved to levels matching or exceeding those of new FGD systems – regardless of age and design. A list of these cost-effective technologies provided by AECOM include:

Liquid Distribution Rings

  • Improved gas-liquid contact
  • Reduced “gas sneakage” along absorber walls and corners
  • Absorber walls protected from spray impingement

Dual-flow Sieve Trays

  • Improved gas-liquid contact
  • Improved gas distribution
  • Reduced pump requirements

 

Design Tools to Support FGD Upgrade Technology

CFD Engineering

  • Improved gas distribution
  • Improved mist eliminator performance
  • Improved oxidation air sparger design

Spray Coverage Design Tools

Mist Eliminator Design Guidelines

Material Selection Guidelines

FGDPRISM

FGD Upgrade Benefits to Your System
  • Greater than 98% SO2 removal
  • Greater than 90% oxidized mercury removal
  • Greater than 70% particulate removal
  • Uninterrupted operation between scheduled outages
  • Zero liquid discharge operation
  • Even and uniform gas distribution
  • No recirculation zones
  • Improved performance through spray zone and mist eliminator
  • Vigorous gas-liquid contact
  • Increased removal performance
  • Reduced or eliminated performance additives
  • Stable and controlled chemistry
  • High regent utilization
  • Improved byproduct quality
  • Minimized scaling
  • Improved mist elimination
  • Improved dewatering, reagent preparation, and wastewater treatment

 

FGD Upgrade Benefits to your Bottom Line
  • Long-term reliability and availability of scrubber
  • Innovative and low-cost air emissions control solutions
  • Reduced or eliminated use of performance additives
  • Ability to switch to lower-cost, higher sulfur fuels
  • Life extension of existing equipment
  • Reduced operating and maintenance costs
  • Improved byproduct quality and properties
 

Related Services & Products
CFD Engineering