Process Engineering, Equipment and Systems 

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EUROPEAN OFFICE • JOAQUIN ARELLANO, 8 • 48930 GETXO • SPAIN • TEL +34 94/480-0242 P3870612.512 

June 22, 2012 

Reference: P-125387 

Domtar Industries, Inc. 

285 Highway 71 S 

Ashdown, AR 71822-8356 

Attention: Ms. Andrea Dieterle 

Subject: Emission Controls for Power Boiler No. 2 

 

Dear Ms. Dieterle: 

The Geoenergy Division of A. H. Lundberg Associates, Inc. is pleased to submit the following 

budget proposal for the supply of a wet ESP emission control system for the No. 2 power boiler 

at the Ashdown Mill. 

In summary, the proposal is to supply an add-on spray scrubber/wet ESP to operate downstream 

of the existing venturi scrubbers. The spray scrubber will utilize sodium hydroxide to absorb SO2

and the wet ESP will collect particulate matter. 

We offer the following comments for your consideration. 

DESIGN GOAL

The goal for this proposed equipment is to 1) meet the anticipated MACT standards for 

particulate matter and 2) provide 90% SO2 reduction to comply with BART requirements. 

To meet the anticipated MACT standards we have designed for an outlet particulate emission rate 

of less than 0.015 lb/MM BTU. As you know, the re-considered MACT requirement proposed 

by the EPA is presently 0.029 lb/MM BTU. However, as of this date a final requirement has not 

been issued by the EPA. If the final requirement is significantly different than 0.029 lb/MM 

BTU the wet ESP can probably be re-sized without a major impact on the scope of the project. 

With regard to the BART regulation, as discussed, there has been no guidance from the 

regulatory authorities. Given this, we have selected 90% SO2 reduction as a common-sense 

approach to the situation. As in the case of the MACT requirements discussed above, if higher 

removal rates are required the equipment offered can probably be re-designed without a major 

impact on the project. 

P.O. Box 597 

Bellevue, Washington 98009 

13201 Bel-Red Road 

Bellevue, Washington 98005 

tel: 425.283.5070 

fax: 425.283.5081 
Domtar Industries, Inc. P-125387 

Mr. Andrea Dieterle 

Page 2 

P3870612.512 

PROCESS CONSIDERATIONS

An add-on spray scrubber/wet ESP is a logical choice because the gas stream is already being 

treated with a wet scrubber. Unlike the previous wet ESP project at the Ashdown Mill no new 

upstream water recycle equipment would be required. Also, there would be no additional process 

water requirement because spent water from the spray scrubber/wet ESP could “feed forward” to 

the scrubber system as make-up. A process flow diagram showing this scheme is included in the 

appendix of the proposal. 

Another advantage of add-on equipment would be that installation could be completed off line 

with final tie-in to be accomplished in a very short period of time. In contrast a modification to 

the existing scrubber to increase pressure drop to enhance efficiency would require substantial 

down time and, in all likelihood a new boiler fan. The new wet ESP could use the existing fan 

for the necessary forced draft requirement. In similar installations we have actually reduced the 

pressure drop on the upstream scrubber to more than make up for any additional pressure drop 

across the wet ESP. 

If you have any questions about the proposal, please feel free to me a call at 425/283-5070. 

Thank you for the opportunity to present this proposal. We look forward to working with you on 

this project. 

Sincerely, 

GEOENERGY DIVISION/A.H. LUNDBERG ASSOCIATES, INC.

Steven A. Jaasund, P.E. 

Manager 

enc: Proposal 

copy: Mr. Rudi Miksa, A.H. Lundberg Associates/Monroe, LA 
A.H. LUNDBERG ASSOCIATES, INC. P-125387 

June 25, 2012 

BUDGET PROPOSAL

SPRAY SCRUBBER/ WET ESP SYSTEM

FOR

DOMTAR INDUSTRIES, INC. 

ASHDOWN, ARKANSAS

Our Representative in Your Area: 

Mr. Rudi Miksa 

A. H. Lundberg Associates, Inc. 

Monroe, LA 

318/361-0165 
P3870612.512

TABLE OF CONTENTS

INTRODUCTION ................................................................................................................. 1

PROCESS DESCRIPTION .................................................................................................... 1

DESIGN BASE ..................................................................................................................... 2

PROPOSED SUPPLY ............................................................................................................ 3

ENERGY REQUIREMENTS ................................................................................................. 4

COMMERCIAL TERMS AND CONDITIONS ......................................................................... 5

CLARIFICATIONS AND WORK BY OTHERS ...................................................................... 5

PRICES ............................................................................................................................... 5

TERMS OF PAYMENT ......................................................................................................... 6

PERFORMANCE WARRANTY ............................................................................................. 7
P-125387 

1 P3870612.512 

INTRODUCTION

The Geoenergy® Division of A.H. Lundberg Associates, Inc. (AHLA) proposes to supply an addon spray scrubber/wet ESP system for the control of SO2 and particulate emissions from the No. 

2 power boiler at the Domtar Industries Pulp Mill in Ashdown, Arkansas. 

The proposal includes two identical gas cleaning trains each including a spray scrubber followed 

be an E-Tube® Wet Electrostatic Precipitator. 

PROCESS DESCRIPTION

The spray scrubber/wet ESP trains will be installed downstream of the existing venturi scrubbers and 

will utilize the main boiler fan on a forced draft basis. We anticipate a maximum of 3 inches w.c. will 

be necessary to overcome the added resistance of the add-on equipment. If this additional pressure is 

not available from the existing fan, the capacity can be gained by reducing the pressure drop 

through your existing scrubber an appropriate amount. This pressure drop reduction will not 

have a significant effect on the size requirements of the new wet ESP. 

The spray scrubbers will be a downflow design utilizing upward facing spray headers to maximize 

liquid to gas contact. The unit will operate at a liquid to gas ratio of 20 gal/1000 acf and will utilize a 

pH adjusted scrubbing solution to affect a minimum of 90% SO2 absorption. Sodium hydroxide will be 

used to maintain pH at the required level. 

After exiting the spray scrubbers, the gas streams will enter the bottom of the two wet ESP units. 

Directional baffles in the bottom of each unit will evenly distribute the gas as it turns upward. 

The gas will then pass through a perforated plate for gas distribution prior to entering the 

electrostatic zone of the wet ESP. 

The electrostatic zone of the wet ESP is comprised of two parallel collection sections. Each 

section is made up of the collection tubes with discharge electrodes supported from above. As 

the gas passes upward through these collection tubes, the entrained particles are charged by high 

voltage and collected on the inner surface of the tubes. 

To promote condensation and wetting of the tube walls, ambient air is blown across the wet ESP 

tube bundle in the manner of a cross-flow air-to-air heat exchanger. This air is then directly 

discharged to the atmosphere. The resultant reduction in the emission stream temperature below 

the saturation temperature (wet bulb temperature) will cause condensation. This condensation 

forms on the internal tube walls thus maintaining wet collection walls, which allows for easy 

removal of the collected particulate through automatic flush cycles. 

After exiting the tubes, the cleaned gas passes through the power grid housing, then the outlet 

plenum at the top of the wet ESP unit. The gases from the unit be discharged through individual 

30-foot stacks mounted on top of each unit. 

Heated purge air is provided to each of the insulators supporting the power grid. The heating of 

the purge air is required to maintain the cleanliness of the insulators. The purge air is heated by 

passing ambient air through the outside of the wet ESP tube bundle. This method of heating the 

purge air also results in condensation forming on the inside wall of the collection tubes for 

improved wetting. 

Each collection section is periodically and independently flushed with clean water to remove the 

collected particulate matter. The flush water cascades from the collection tubes to flush the inlet 

perforated air distribution plate. It then falls down through the inlet plenum to be collected in the 

sump at the bottom of each unit. The water in this sump will then be pumped upstream to act as 

make-up water for the upstream scrubber. 
P-125387 

2 P3870612.512 

A process flow diagram and a general arrangement drawings for the system proposed are 

included in the appendix of this proposal. Also included is a summary of the features of the ETube Wet Electrostatic Precipitators. 

DESIGN BASE

The following process information will be used for the design of the spray scrubber/wet ESP 

system. 

No. 2 Power Boiler Design Conditions 

Fuel Coal, bark, natural gas, TDF, (planning on 

fuel oil in future) 

Boiler Type Stoker 

Volumetric Gas Flow (scfm dry) 142,737 

Scrubber Exit Gas Temp. (°F) 136 

Exit Moisture (% wt) 12.3 

PM Loading (lb/hr) 44.6 

SO2 Concentration (ppmv) 235.9 

The 

The spray scrubber/wet ESP equipment offered will be designed to reduce the SO2 concentration 

by 90% and the particulate matter to less than 0.015 lb/MM BTU at the outlet. 
P-125387 

3 P3870612.512 

PROPOSED SUPPLY 

The following list summarizes the major components of the systems offered to treat the emissions 

from the power boiler. 

 Item Quantity Description 

1 One (1) lot System Engineering, including process flow diagrams, process 

and instrument diagrams, general arrangement drawings, 

functional narrative of the logic, assembly drawings, 

instrument specifications, pump specifications, and operation 

and maintenance manual complete with spare parts lists 

2 Two (2) only Spray scrubbers; T-316L SS, downflow design with recycle 

pump, tank and piping 

3 Two (2) only Model 1010-378 E-Tube® Wet ESP units; T-316L SS wetted 

parts, tubular type upflow with rigid mast discharge electrodes 

4 Four (4) only High Voltage Power Supplies, IGBT forced air cooled, 480 

volt/3 phase/60 Hz 

5 Two (2) only Purge Air System, including fan with 5 hp motor, inlet filter 

and ductwork 

6 Two (2) only Flush System, including flush tank and piping system in 

carbon steel and pump in ductile iron with stainless steel trim 

7 Two (2) lots Support and access steel 

 8 Two (2) lots Field instrumentation 

 9 One (1) lot Commissioning, start-up and training 

10 One (1) lot Local wiring of all electrical elements 

11 One (1) lot Complete mechanical installation 
P-125387 

4 P3870612.512 

ENERGY REQUIREMENTS

The following table shows the expected energy demands of the wet ESP system described in this 

proposal. 

Spray Scrubber/Wet ESP Energy Requirements 

Scrubber pumps (kW) 108 

High voltage power supplies (kW) 266 

Insulator purge air fans (kW) 2.2 

Insulator heaters (kW)* 48 

Tube cooling fans (kW) 140 

Flange to flange pressure drop (in. w.c.) 3 

*Note: Insulator electric heaters only operate during start up. 
P-125387 

5 P3870612.512 

COMMERCIAL TERMS AND CONDITIONS

CLARIFICATIONS AND WORK BY OTHERS

1. Ducting from the existing scrubber to the inlet flange of the spray scrubbers is not included 

2. The cost of a crane to lift the equipment offered to the top of the No. 2 boiler building is not 

included 

3. Structural steel to the bottom of the wet ESPs is not included. Structural and access steel 

above this level is included. 

4. Civil work or improvements to existing structures is not included. AHLA will provide 

foundation-loading information. 

5. Performance testing is not included 

6. The performance guarantee includes a flush cycle averaged into the results. 

7. AHLA will require access to mill drawings and records required to design the proposed 

system. 

8. The client is responsible for obtaining all necessary building/environmental permits, taxes 

and professional engineering fees. 

9. The client is to provide a lay down area close to the work site, as well as field fabrication 

area for piping, etc. 

10. The client is to supply steam and process water as required by the erection crew free of 

charge. Also parking area, trailer space(s), and access to phone lines. Phone line hookup 

will be by AHLA. AHLA is to supply electrical power for construction. 

11. Construction crews may be union or non-union. 

12. The client is responsible for the removal, handling, disposal, or replacement of all asbestos 

materials, lead paint, or contaminated soils that may be encountered. 

13. The client is to provide an on-site location for construction debris. 

14. Any required demolition work is not included in our bid. 

PRICES

The budget price for the spray scrubber/wet ESP system, Items 1-11, is: 

Five million two hundred seventy thousand dollars 

$5,270,000.00 

These prices are FOB mill site. Prices do not include applicable taxes. All prices are in U.S. 

dollars. 

The purchaser assumes liability for payment to the state of any Sales or Use tax if he uses or 

consumes the property herein purchased in such a way as to render the sale subject to tax. 
P-125387 

6 P3870612.512 

TERMS OF PAYMENT

The terms of payment shall be: 

5% with purchase order. 

10% with submittal of approval drawings (process flow sheets, equipment drawings 

and general arrangements

25% with order placed for major equipment (WESP) 

10% on delivery of 10′′ diameter collection electrodes to the shop

5% on construction mobilization

15% on delivery of WESP to the mill; partial shipment allowed 

25% on monthly percent completion of construction 

5% on satisfaction of performance warranty on each unit, not to exceed six (6) months 

from shipment. This may be secured by a letter of credit at AHLA’s option, and 

due at shipment. 

Payment will be due thirty (30) days after date of invoice. 

ERECTION ADVISOR

If the Buyer elects to be responsible for the installation of the wet ESP equipment the services 

of a qualified erection advisor can be made available at a rate of $1350.00 per man day (man 

day being ten (10) hours) plus expenses. Charges after ten (10) hours will be $170.00 per 

hour. Expenses are to include first class food and lodging, economy travel to and from plant 

site to lodging, and travel to and from project from the normal domicile of the engineer. 

TRAINING SERVICES

Training is included as a part of the equipment package. The additional services of a trainer 

can be made available at a rate of $1,500.00 per man day (man day being eight (8) hours) plus 

expenses. Charges after eight (8) hours will be $210.00 per hour. Expenses are to include 

first class food and lodging, economy travel to and from plant site to lodging, and travel to 

and from project from the normal domicile of the engineer. 

START-UP SERVICES

Start-up services are included as a part of the equipment package. The additional services of 

an engineer can be made available at a rate of $1350.00 per man day (man day being ten (10) 

hours), plus expenses. Charges after ten (10) hours will be $170.00 per hour. Expenses are to 

include first class food and lodging, economy travel to and from plant site to lodging, and 

travel to and from project from the normal domicile of the engineer. 

SHIPMENT

Shipment will be made twenty-six (26) weeks after receipt of order. Shipment schedule 

requires that approval drawings, when submitted, will be returned within two (2) weeks. The 

time to complete erection is very dependent on site conditions. Normally equipment of this 

size can be installed in less than 8 weeks. 
P-125387 

7 P3870612.512 

CANCELLATION 

Should Purchaser place an order for the equipment proposed and later find it necessary to 

cancel, Purchaser shall pay the full amount for any equipment, portions thereof, or orders for 

which Vendor is liable, plus charges for engineering work completed at that time, plus fifteen 

(15) percent of the total costs incurred. 

PERFORMANCE WARRANTY

A.H. Lundberg Associates, Inc. (AHLA) will provide the equipment and process engineering 

as specified in this proposal for a complete and operable system and guarantee that 

1) the inlet SO2 concentration will be reduced by 90% but no lower than 20 ppmv and, 

2) the particulate emissions at the outlet of the two wet ESP trains will be less than 0.015 

pounds/million BTU. 

These guarantees are in effect when the system is operated in and supplied with the service 

conditions in general accordance with the Design Base of this proposal. 

US EPA Method 1, 2, 3, 4, and 6 shall be used to quantify the SO2 concentration at the outlet 

of the equipment. 

US EPA Methods 1, 2, 3, 4 and 5 shall be used to quantify the particulate emissions at the 

outlet of the wet ESP units. The basis for conversion of measured PM emission concentration 

values to lb/MMBtu units shall be per EPA Method 19. 

Acceptance tests must be performed within three (3) months after initial start-up of the 

equipment, not to exceed six (6) months after final shipment. The testing shall be performed 

by an independent third party that is acceptable to both Buyer and Seller. 

The warranty shall be fully satisfied and AHLA discharged there from upon the earlier of: (a) 

obtaining guaranteed performance by the testing described above, (b) the expiration of three 

(3) months from initial start-up with no testing being made, (c) the expiration of six (6) 

months from final shipment without a test being made. 

If the guaranteed performance is not obtained, then AHLA shall have the right, and if 

required by the Owners, the obligation, to visit the installation to determine the cause of such 

failure. It is a condition of this guarantee that the Owner will cooperate with AHLA in the 

making of further tests and make available necessary personnel, feed and operating conditions 

to enable AHLA to conduct such tests. The tests will be paid for by the purchaser. 

If failure to obtain guaranteed performance on the above is due to defect in AHLA-supplied 

equipment, design, or engineering, then AHLA will, at its expense, supply the equipment or 

process engineering it deems necessary until such performance is met, up to a limit of the 

contract price. Any remedy includes an equivalent scope of installation as outlined elsewhere 

in this proposal. 

If failure to obtain guaranteed performance is due to the Purchaser’s fault in operation, or in 

not providing proper feed or other specified operating conditions, the Owner shall pay the 

living and traveling expenses of AHLA personnel visiting the installation. In addition, the 

Owner shall pay the sum of $1,300.00 per man-day or fraction thereof for such personnel. 

Nevertheless, such personnel will, on request, work with the Owner at the Owner's expense in 

making necessary corrections to accommodate the changed conditions. 
P-125387 

8 P3870612.512 

MATERIAL AND WORKMANSHIP

We guarantee every part of the apparatus delivered in accordance with this proposal will be of 

proper material and workmanship, and agree to repair any part or parts which may prove 

defective in material or workmanship within twelve months from start up of equipment but 

not to exceed eighteen months from date of shipment on each unit, it being agreed that such 

replacement is the full extent of our liability in this connection. Corrosion or wear from 

abrasion shall not be considered as defective materials. The best engineering practice will 

always be followed and materials used will be clearly specified. We shall not be held liable 

or responsible for work done or expense incurred in connection with repairs, replacements, 

alterations, or additions made, except on our written authority. 

VENDOR’S RESPONSIBILITY

In the course of design of processes and/or equipment where the Vendor provides process 

flow diagrams, layouts, and installation diagrams, it is anticipated that Vendor furnished 

design will be followed. Changes in design without written approval of the Vendor will 

relieve the Vendor of responsibility for performance of the supplied equipment. 

DRAWINGS LIMITATION

All Vendor drawings supplied to the customer or his engineer under an order resulting from 

this proposal will remain the property of the Vendor and are conditionally loaned with the 

understanding that they will not be copied or used except as authorized by us. Reuse of the 

designs as shown on the drawings for another project is specifically prohibited. 

CONFIDENTIALITY OF PROPOSAL INFORMATION

This proposal contains confidential information and remains the property of A.H. Lundberg 

Associates, Inc., and is conditionally loaned. The information contained herein is not to be 

shared with any party except those within the Buyer’s company who are involved in its 

evaluation or outside consultants who are assisting the Buyer with this specific project. 

Specifically prohibited is the distribution of such information to any individual or business 

deemed to be a competitor by AHLA 

SECURITY INTEREST

AHLA reserves the right to request a security interest in the materials provided as a part of 

this proposal, and Buyer agrees to provide information needed to assist AHLA in obtaining a 

security interest and to execute such documents AHLA reasonably requests to create a 

security interest. Security interest language is available on request. 
P-125387 

9 P3870612.512 

We appreciate the opportunity to present this proposal and look forward to your favorable 

consideration. 

Sincerely, 

GEOENERGY DIVISION/A.H. LUNDBERG ASSOCIATES, INC. 

V 

Steven A. Jaasund, P.E. 

Attachments: General Arrangement Drawings 

 Process Flow Diagram 

 Wet ESP Features 
ATTACHMENTS



P-125387 

1 P3870612.512 

WET ESP FEATURES

The E-Tube® wet ESP design is an extremely efficient and cost effective device for the removal 

of particulate from a solid fuel fired boiler. Below is a discussion of the various design elements 

of the E-Tube contributing to this performance. 

Upflow 

Due to the benign nature of the particulate 

being collected in this application, the 

upflow arrangement provides certain 

benefits. In the upflow configuration, the 

inlet plenum acts as a quiescent zone, 

allowing entrained water droplets to fall 

out of the gas stream. As the inlet plenum 

is at the bottom of the wet ESP, the water 

does not fall into the tube collection 

section as it would in a downflow 

arrangement. Thus, there is no need for 

an inlet droplet separator. (With the 

downflow configuration, these water 

droplets raining into the collection section adversely affect the performance of the system and 

need to be removed prior to entering the wet ESP. A cyclone separator is most commonly used 

for this service. The cyclone adds capital cost to the project and more importantly, additional 

operating costs due to its pressure drop.) 

Tube Cooling 

The wet ESP systems offered will include an 

innovative tube cooling feature to further enhance 

performance and operability. The tube cooling 

feature works like this. 

The gas stream leaving the existing scrubbers and 

entering the wet ESP collection sections is 

saturated with water vapor. This saturated gas 

stream has small water droplets entrained in it. 

In the up-flow mode, the wet ESP preferentially 

removes the water droplets prior to removing the 

smaller sub micron particles. This occurs in the 

lower portion of the tube bundle. In order to wet 

the entire length of the collection tube, ambient 

air is pulled across the tube bundle in the manner 

of a shell and tube, air-to-air heat exchanger. The 

axial fans and hoods shown on the right side of 

this illustration ensure proper air distribution. 
P-125387 

2 P3870612.512 

Star II Electrode 

Extensive research culminated 

with the development of the 

Star II discharge electrode. 

The high performance discs 

increase the corona discharge to 

maximize the particle charging 

capacity. This ability to 

discharge more current at 

voltage results in less required 

collection surface. This greater 

discharging capacity is coupled 

with ability to deliver more 

power to the Star II discharge 

electrode. The high frequency, 

high voltage power supply, 

discussed further below, delivers 

significantly more power to the 

discharge probes. 

Round Tubes 

The collection electrodes are 

round tubes. The discrete, 

round-tube construction offers a 

distinct advantage in corrosive 

applications (see comparison to 

hex-tube arrangement below). 

Per the diagram, both systems 

experience general corrosion. 

On the hex tube design, it occurs 

on both sides of the collection 

plate, whereas on the round tube 

it occurs only on the inside 

surface that is in contact with 

the process. Due to the 

difficulties in manufacturing the 

hex bundle, the plate material is 

similar thickness to the round 

tube, resulting in a shorter life. 

Additional corrosion mechanisms occurring in the hex bundle, but not on the round tube include 

crevice and stress corrosion. These are set up with the construction of the hex bundle, including 

bending the metal in some corners (stress) and skip welding where other corners come together 

(crevice). 

Finally, the round tube also has the most uniform electrical field for the highest efficiency. 
P-125387 

3 P3870612.512 

High Frequency Power Supply 

The efficiency of the wet ESP is 

dependent on the migration velocity of a 

particle and the amount of collection area. 

The migration velocity is a function of the 

square of the voltage applied. Thus, more 

area can be provided or a higher voltage 

can be applied. The transformer/rectifiers 

on a Geoenergy® E-Tube® wet ESP are 

high frequency, high voltage units. The 

high frequency units maximize the voltage 

to the system, providing the highest 

voltage and highest efficiency for a given 

design and collection area. 

General 

Corrosion

Crevice

Corrosion

Stress Corrosion

General 

Corrosion

General 

Corrosion

Crevice

Corrosion

Stress Corrosion

General 

Corrosion

Corrosion Mechanisms in Tubes

Hex Round
P-125387 

4 P3870612.512 

Innovative Purge Air System 

Heated purge air is provided to each of 

the insulators supporting the power grid. 

The heating of the purge air is required to 

maintain the dryness and cleanliness of the 

insulators. The purge air is heated by 

passing ambient air through the outside of 

the wet ESP tube bundle. An auxiliary 

electric heater is also included for start-up. 

We have significant experience with the 

design of the compartments holding the 

insulators. They are outboard of the wet 

ESP units, designed to avoid any aspirating 

of dirty gas back into the compartment to 

provide long life on the insulators. 

 

SUMMARY OF BENEFITS

The E-Tube® wet ESP technology provides for a smaller, more efficient system relative to dry 

ESP technology. 

• The wet system eliminates the fire potential present in dry systems. 

• Upflow configuration eliminates the need for an inlet water droplet separation device, 

removing both the initial capital and the ongoing operational costs due to increased 

pressure drops. 

• Tube cooling insures collecting surface cleanliness and maximum voltage 

• The Star II discharge probes maximize the corona discharge and thus the particle 

charging capacity of the system. 

• Round tubes for the collection surface provide the best performance and longevity. 

• High frequency, high voltage power supply provides the highest voltage to the system 

to maximize the efficiency. 

• The heat from the process gases supplies the heating of the insulator purge air; the 

energy requirement from outside sources is minimized. 

In total, the E-Tube wet ESP provides the highest performance possible to maximize collection 

efficiency.