Babcock Power Environmental Inc., a Babcock 

Power Inc. company, provides fully integrated 

environmental solutions for utility power plants, 

waste-to-energy facilities, and large industrial 

applications worldwide. With more than 30 years of 

experience in designing and installing Wet Flue Gas 

Desulfurization (WFGD) systems, Babcock Power 

Environmental Inc. can apply its technology and 

experience to upgrade any OEM’s WFGD system. 

Babcock Power Environmental upgrades existing 

scrubbers to meet today’s more stringent emissions 

regulations and achieve higher performance levels. 

Typically, the intent is to increase SO2

 removal 

efficiency to 97-99%, while minimizing additional 

pressure drop and energy consumption.

WFGD scrubber upgrades normally involve applying 

new technology to existing systems to achieve 

optimal efficiency. Initially, an understanding of 

current problems is essential. Older models often 

have poor gas distribution and fail to remove 

significant amounts of SO2

. They also present 

inefficient spray patterns over the cross section of 

the absorber. Babcock Power Environmental can 

successfully overcome these problems by utilizing 

its world-leading technology and experience.

Contact Babcock Power Environmental Inc. to 

meet emissions regulations and improve the 

efficiency of your WFGD.

TECHNICAL OVERVIEW

Wet Flue Gas Desulfurization 

Scrubber Upgrades 

Babcock Power Environmental Inc. www.babcockpower.com

Benefits

Scrubber Upgrades

• Low cost solution vs. new installation

• Catch up on 20 years of technology

• Meet today’s requirements with yesterday’s 

dollars

• Higher SO2 reduction with improved 

energy efficiency

CFD Modeling

• Results in better gas distribution

• Simulates droplets and full spray coverage over 

absorber(s)

• Ensures proper flow along walls

• Identifies areas requiring additional nozzles for 

proper liquid and gas distribution

Bidirectional Nozzles Installed

• Wider-angle spray cone ensures efficient spray 

pattern through the spray zone

• Increase gas - liquid collisions

• Dual direction allows for complete coverage 

throughout the total spray zone

Wall Baffles

• Improve distribution of flue gas over entire 

cross section

• Reduce “gas sneakage” along absorber walls 

and corners

• Minimize pressure drop

*Delta Wings furnished utilize technology under an exclusive license with Balcke-Dürr

GmbH and from other Babcock Power Inc. proprietary sources.

 

Bidirectional

Spray Nozzles

Bidirectional

Spray Nozzles Wall Rings

a Babcock Power Inc. company
Strategic Process

The process begins with a complete analysis of the existing system design and performance. Physical and 

Computational Fluid Dynamics (CFD) flow modeling follow this to optimize inlet gas distribution and limit the 

amount of slurry deposition on the inlet duct. Slurry spray nozzle tests are then conducted to ensure new 

nozzles will have similar flow and pressure criteria. Bidirectional nozzles, however, will be installed regardless 

of the original design, with wider-angle spray cones to provide complete coverage of the spray zone and 

increased gas-liquid collisions. Wall baffles are designed and installed in each absorber to direct and better 

distribute flue gas over the entire cross section of the absorber, as well as minimize or eliminate “gas sneakage” 

along the absorber walls and corners. These strategic steps improve gas flow distribution and liquid-to-gas 

contact, ultimately increasing the absorber’s effectiveness in removing SO2

 from the flue gas.

Babcock Power Environmental Inc. • 5 Neponset Street, PO Box 15404, Worcester, MA 01615-0040 tel: 508-852-7100 • www.babcockpower.com

TECHNICAL OVERVIEW

Wet Flue Gas Desulfurization 

Scrubber Upgrades

BPE-TO-0011-v3-2013

Unit Flue Gas SO2, 

lb/MBtu

Starting SO2, 

Efficiency

Upgrade SO2,

Efficiency

550 MW 6.5 -91 % >99%

390 MW 8.0 93.5 % ~98 %

2 x 600 MW 2.0 <94% ~98%

Note: Coal type remained the same as original for all three projects

Safety3

People. Power. Projects. We’re giving safety the third degree. Babcock Power Inc. and its subsidiaries place the safety, health and security of our people at the core of our company values. Our team is our most valuable 

resource, generating solutions everyday to deliver safe, clean, reliable energy globally. With a keen focus on safety, Babcock Power Inc. conducts business in a manner that protects our people, our customers and the 

environment. From innovation to generation, we are proud of our award-winning safety record and are committed to operating with integrity and excellence.

The data contained herein is solely for your information and is not offered, or to be construed, as a warranty or contractual responsibility. © Babcock Power Environmental Inc., 2013 

a Babcock Power Inc. company