### A URS and MHIA Company 

# Double Contact Flow Scrubber

**Advanced FGD Technology for Your Multi-pollutant Control Needs** 

# SO 2ADVATECH formed in 2002 as a joint venture of URS Corporation and Mitsubishi Heavy Industries America (MHIA) to bring the unique and highly effective Double Contact Flow Scrubber (DCFS) wet FGD technology to the U.S. marketplace. As a jointly owned company, ADVATECH pairs MHI’s technology with the engineering, design, procurement, and construction (EPC) services of URS. The DCFS is unique in that the slurry sprayed from each nozzle con

tacts the flue gas twice—as it sprays upward and as it rains down. This
double contact provides more efficient mass transfer and higher SO 2 removal per unit of L/G. ADVATECH offers both a Single Tower and Twin Tower DCFS to cost effectively achieve your removal requirements. The Single Tower DCFS is for units burning low- to medium-sulfur fuel, and the Twin Tower DCFS is for units burning medium- to high-sulfur fuel. Through nearly five decades of experience, and years of research and development, MHI has continuously made design improvements that augment performance and reliability while driving down O&M costs. This
has resulted in a design capable of achieving greater than 99% SO 2 removal with 100% availability , regardless of boiler size and/or fuel sulfur content. 

# Single Tower DCFS 

# Features Common to the DCFS

Low profile – The DCFS technology introduces all of the recycle spray at a single elevation, resulting in a shorter absorber than a traditional open spray tower or tray tower.The low elevation of the spray header and lowpressure spray nozzles employed in the design translates into low recycle pump head, resulting in lower overall power consumption

. 

### Single spray level – Since there is only a single elevation of spray nozzles supplied by a common header, the spare recycle pump does not require a spare spray header. Furthermore, the potential for header-to-header erosion is reduced. Since the spray header is always in service with slurry constantly raining down on it, it is self cleaning, resulting in decreased maintenance

.



### Efficient oxidation and agitation – The DCFS uses the patented Jet Air Sparger (JAS) technology for efficient oxidation and agitation of the absorber slurry. The JAS acts as an eductor, making use of existing recycle pump capacity to induce air into the absorber reaction tank. For low-sulfur systems, a series of JAS can educt enough ambient air into the process to eliminate the need for oxidation air blowers

. For high-sulfur systems, smaller capacity blowers are required. In all instances, agitator requirements are minimized

. 

### Fountain spray nozzles – Our proprietary nozzles have no internals and a large free passage (2"), making them much less susceptible to plugging and erosion , longer lasting, and less maintenance intensive. Since the nozzles generate a fountain, they can be located close to each other and the absorber walls without risk of increased erosion from direct impingement . The tighter nozzle spacing reduces gas sneakage and helps to ensure high removal efficiency.

Slurry Distribution Level

2

# ADVATECH DCFS Offers:

• The highest demonstrated

per for mance worldwide

– 99.8% SO 2 removal efficiency

– Ultra-high removal through a wide

range of SO 2 concentrations (up to 7,800 ppm demonstrated)

• High reliability

– 100% reliability demonstrated in

plants operating domestically and internationally

• Simple operation and maintenance

– Forgiving to fuel fluctuations

– Easy access and maintenance

– Low power consumption

• Attractive economics driven by:

– Superior low-cost technology

– Project and technology integration

– Optimized business structure

• The largest installed WFGD

e

xperience base

– 82,000 MW worldwide

– >20,000 MW domestic

• The largest installed base of

tile-lined concrete absorbers

– 10,200 MW domestic 

# Twin Tower DCFS

Carbon Steel Inlet Duct – Flue gas enters the vessel at the top of the first tower, placing the wet-dry interface approximately 10 feet into the vessel. The nature of this design makes it impossible to get recycle slurry into the absorber inlet ductwork , thus avoiding the need for exotic materials of construction.* 

### Expandability – The common header allows for the future ability to treat higher-sulfur fuel or achieve higher removal efficiencies with minimal, upfront capital investment. Provisions can be designed into the system that allow for the future procurement and installation of recycle pumps and, if necessary, other equipment at a reasonable retrofit cost.



### Stable and forgiving operation – The DCFS is designed to operate at 30 wt% suspended solids , twice that of competing technologies. The resulting buffer capacity and close proximity of nucleation sites provides for stable operation and low scaling potential. The DCFS is less susceptible to fluctuations in performance as a result of variations in gas flow rate or composition, and high removal efficiency can be achieved without the need for organic acid addition. 

### Top-mounted agitators – Adequate agitation and oxidation are critical to scale-free operation. The Twin Tower DCFS has the added advantage of using top-mounted agitators installed between the two towers, which ensures top-to-bottom mixing of the reaction tank slurry. * 

### Maintainability – The ease of access and minimization of internals make the DCFS the lowest cost-to-maintain absorber module in the world . There are no oxidation air spargers to plug, only a single spray header elevation to inspect and maintain, no scaffolding requirements to inspect the slurry nozzles, commonality of equipment, and easy access to all equipment.

Fountains Spray Nozzle Jet Air Sparger (JAS) Recycle Pumps

3 * Feature specific to Twin Tower DCFS Based upon ADVATECH and MHI experience4 

# A

**Cost-Effective and Space Conscious Solution for Air Quality Control**

ADVATECH has developed, standardized, and implemented a simplified and integrated wet FGD process that requires less capital investment and a smaller footprint than traditional designs. The Simplified DCFS, shown above, is designed specifically for small and industrial boilers, and has a total installed cost of nominally $200/KW. The Simplified DCFS eliminates costly and, in some instances, maintenance-intensive capital equipment. Furthermore, its design is close coupled to minimize ductwork, piping, and electrical runs, as well as overall space requirements. Specific features include the following:

Pre-ground limestone Rather than grinding limestone on site, pre-ground limestone is procured. The powdered limestone is directly fed to the absorber reaction tank to control pH, eliminating the ball mill, tank, agitator, and pump requirements associated with grinding limestone and handling a slurry

. Direct feed to primary dewatering Since the DCFS is designed to operate at 30 wt% solids, in most instances only a single dewatering stage is required. As a result, slurry from the reaction tank can be directly fed to the locally placed belt filter using existing recycle pump capacity.

Integrated stack For stack height requirements of approximately 300 feet or less, ADVATECH offers a wet FGD design in which the stack is mounted directly to the top of the absorber vessel. This integrated design dramatically reduces both footprint and capital cost requirements. Through the avoidance of a stand-alone stack, expensive FGD-outlet ductwork is eliminated, and both foundation and access requirements are reduced. 

# ADVATECH’s Simplified DCFS

Integrated Stack >750 MW of Operating Capacity



### Pre-Ground Limestone System

45,000 MW of Operating Capacity 

### Direct-Feed Dewatering 23,000 MW of Operating CapacityADVATECH takes an integrated approach to meeting the stringent emission requirements for existing and new plants. By combining proprietary MHI technologies with established commercial technologies, ADVATECH maximizes the co-benefits of each process component for achieving multi-pollutant control. As a result, we are able to offer sustained, reliable performance while minimizing total lifecycle cost. The centerpiece of ADVA TECH’s multi-pollutant control strategy is the DCFS. The DCFS, while highly efficient at removing acid gases, is
also beneficial for controlling other pollutants. Particulate emissions can be further reduced by up to 95 percent when located downstream of an ESP. In tandem with a reagent injection process, wet ESP , or High Efficiency System to control acid mist, opacity levels can be reduced to single digits. The DCFS is also efficient in removing oxidized mercury. In com bi

nation with an SCR, halogen injection, PAC injection, and/or ORP control, 95% or greater removal of total mercury (from coal pile to stack)
can be achieved. For plants where the wet FGD system needs to operate “closed loop” to comply with Zero Liquid Discharge (ZLD) requirements,
A dvatech can either design a DCFS where the only chloride purge is with the gypsum solids, or supply one of our proprietary ZLD technologies. Our Wastewater Spray Dryer (WSD) technology is a low-cost means of complying with ZLD requirements while still allowing operation of the wet FGD
at economical chloride levels. W ith the WSD, the required liquid purge from the wet FGD process is added to a spray dryer installed in a slipstream that bypasses the air heater. The chlorides and other dissolved species form solid particulates that are removed from the flue gas with the fly ash in the particulate control device. As a result, a liquid purge from the plant is completely eliminated, as is a costly wastewater treatment process. 

# An Integrated Approach to Multi-Pollutant Control 

# Multi-pollutant Control

56 

### ADVATECH Domestic Experience URS is the largest provider of engineering, design, construction, and start-up support for commercially
available air emission controls systems, and provides clients with the appropriate technology mix and emissions strategy to bring them into regulatory compliance for the lowest installed and lifecycle cost.

Plant / Unit Utility Capacity Coal Sulfur S0 2 Removal Absorber Materials Scope of Work

Paradise 3 TVA 1,060 3% 98% 6% Moly / 2205 Full EPC

Gorgas 8-10 Alabama Power Company / Southern Company 1,021 2% 98% Stebbins EP

Bull Run 1 TVA 920 2% 98% 6% Moly / 2205 Full EPC

Hammond 1-4 Georgia Power Company / Southern Company 800 2% 98% Stebbins EP

Harding Street 7 AES 465 3.6% 97% 6% Moly Full EPC

Kingston 1-9 TVA 2 x 755 2% 98% 2205 Full EPC

Miller 1-4 Alabama Power Company / Southern Company 4 x 660 0.4% / 1% 98% Stebbins EP

Scherer 1-4* Georgia Power Company / Southern Company 4 x 818 0.3% / 1.5% 98% / 96% Stebbins EP

Newton 1-2** Ameren Energy Resources 2 x 670 0.57% 98% Stebbins Full EPC

Daniel 1-2** Mississippi Power Company / Southern Company 2 x 530 0.33% / 1.5% 98% / 96% Stebbins EP Process Island

* Partially operational as of August 2011 ** Not yet operational 

# Unrivaled Experience

WFGD Upgrades 45,000 MW
FGD Turnkey Systems 41,000 MW
Domestic Wet FGD Systems >20,000 MW

SO 3 Control Systems: SBS 15,000 MW WESP* 4,300 MW High Efficiency System 7,200 MW

SCR 24,000 MW

*Located at stack inlet 

### URS & MHI Domestic AQCS Experience MHI is the world’s leading supplier of FGD systems. The first system was installed in 1964 and, today, over 82,000 MW of wet FGD technology is in operation on more than 214 boilers in 14 countries.
ADVA TECH has successfully delivered more than 14,000 MW of Brownfield wet FGD capacity to the U.S. utility industry. The scope of our services range from engineering and procurement to full EPC, and all of our operating installations
continue to
demonstrate exceptional performance. Installed FGD Capacity 82,000 MW

FGD Orders Since 1964 214 FGDs
FGD Domestic Experience >20,000 MW
Highest SO 2 Guaranteed Removal 99.80%
Highest SO 2 Removal w/o Additives 99.90%
Highest SO 2 Concentration 7,800 ppm
Largest Single Absorber* 1,021 MW
Longest Time Between Outages 4 yrs
Spare Modules Installed None
Availability, Single Module 99.9% / 18 yrs 

### Highlights of MHI’s Worldwide Wet FGD Experience

* Based on flue gas volume7 

## n TVA – Paradise Kentucky 1 x 1,060 MW Twin T ower DCFS Absorber

Boilers 1 x 1,060 MW Design “S” Fuel 3.0% Design Gas Volume, ACFM 4,028,000 Guaranteed Removal 98% ADVA TECH Scope of Supply Full EPC Absorber Materials 6% Moly / 2205 Award Date / Operation Date 2002 / Fall 2006 This project was the first application of the ADV ATECH DCFS process in the U.S. and the first unit for the system-wide contract with TVA. It was a full EPC con

tract with balance-of-plant project scope, including the stack. At the time of its design, it was the largest single absorber in the world.



## n TVA – Bull Run Tennessee 1 x 920 MW Twin T ower DCFS Absorber

Boilers 1 x 920 MW Design “S” Fuel 2.0% Design Gas Volume, ACFM 3,065,000 Guaranteed Removal 98% ADVA TECH Scope of Supply Full EPC Absorber Materials 6% Moly / 2205 Award Date / Operation Date 2005 / Fall 2008 This project included a full EPC contract with balance-of -plant project scope, including the stack. It was selected for Engineering News-Record Project of the Year, 2009. 

## n Southern Company – Gorgas Alabama Power 1 x 1,021 MW Twin T ower DCFS Absorber

Boilers 1 x 800 MW, 2 x 110 MW Design “S” F uel 2.0% Design Gas Volume, ACFM 4,020,000 Guaranteed Removal 98% ADVA TECH Scope of Supply EP Supply Process Islands Absorber Materials Concrete Tile Lined (Stebbins) Award Date / Operation Date 2005 / Dec 2007 We started big. Not only was Gorgas ADV ATECH’s first application of a Stebbins, semplate-lined, concrete absorber, but it is the largest absorber vessel in the world in terms of gas volume and the first application of a DCFS designed to treat multiple boilers. 

# U.S. Commercial Experience

## n IPL – Harding Street Indiana 1 x 465 MW Twin T ower DCFS Absorber

Boilers 1 x 465 MW Design “S” Fuel 3.6% Design Gas Volume, ACFM 1,690,000 Guaranteed Removal 97% ADVA TECH Scope of Supply Full EPC Absorber Materials 6% Moly Award Date / Operation Date 2005 / Sept 2007 This full EPC contract included balance-of-plant project scope such as reagent receiving/prep, gypsum dewatering/loadout, and stack. Executed at a congested site with a tight schedule, the project required processing high-sulfur fuel with high SO 2 removal while producing wallboard-grade gypsum. 

## n Southern Company – Hammond Georgia Power 1 x 800 MW Twin T ower DCFS Absorber

Boilers 3 x 125 MW, 1 x 425 MW Design “S” F uel 2% Design Gas Volume, ACFM 3,026,000 Guaranteed Removal 98% ADVA TECH Scope of Supply EP Supply Process Island and BOP Absorber Materials Concrete Tile Lined (Stebbins) Award Date / Operation Date 2005 / July 2008 Four boilers are treated by a single absorber module while maintaining ultra-high SO 2 removal and producing wallboard-grade gypsum. Procurement of the Stebbins absorber vessel was excluded from ADVATECH’s scope of supply.



## n TVA – Kingston Tennessee 

### 2 x 755 (1,510) MW Twin T ower DCFS Absorber

Boilers 4 x 140 MW, 5 x 190 MW Design “S” F uel 3.0% Design Gas Volume, ACFM 2,915,000 per Absorber Guaranteed Removal 98% ADVA TECH Scope of Supply Full EPC Absorber Materials 2205 Award Date / Operation Date 2005 / Nov 2009, April 2010 This project brought the challenge of designing a system capable of processing flue gas from nine boilers using two twin tower DCFS alloy absorbers. The scope included full EPC for two process islands and all balance-of-plant requirements, including stack.

8

## n Southern Company – Scherer Georgia Power 

### 4 x 818 (3,272) MW Single Tower DCFS Absorber
Boilers 4 x 818 MW Design “S” Fuel 0.3 / 1.5% Design Gas Volume, ACFM 3,710,000 / 3,507,000 Guaranteed Removal 98% / 96% ADVA TECH Scope of Supply EP Supply Process Island Absorber Materials Concrete Tile Lined (Stebbins) Award Date / Operation Date 2008 / 2010-2013 The four single-tower absorbers are designed to achieve 98% SO 2 removal when burning low-sulfur PRB coal, while allowing future expandability to treat a higher sulfur fuel with minimal upfront cost and a modest cost of retrofit. Procurement of the Stebbins absorber vessel was excluded from ADVA TECH’s scope of supply.



## n Ameren Energy Resources – Newton Station Illinois 

### 2 x 670 (1,340) MW Single Tower DCFS Absorber
Boilers 2 x 670 MW Design “S” Fuel 0.6% Design Gas Volume, ACFM 2,700,000 Guaranteed Removal 98% ADVA TECH Scope of Supply Full EPC Absorber Materials Concrete Tile Lined (Stebbins) Award Date / Operation Date Sept 2008 / Under Construction This project represents a full EPC contract with direct hire construction and bal

ance-of -plant project scope, including the stack. Design features include the use of pre-ground limestone, gypsum dewatering, and a common pump building for the two absorbers.



## n Southern Company – Daniel Mississippi Power 

### 2 x 530 (1,060) MW Single Tower DCFS Absorber
Boilers 2 x 530 MW Design “S” Fuel 0.33% Design Gas Volume, ACFM 1,900,097 Guaranteed Removal 98% ADVA TECH Scope of Supply EP Supply Process Island Absorber Materials Concrete Tile Lined (Stebbins) Award Date / Operation Date Jan 2011 / Feb & Mar 2015 The two single-tower absorbers are designed to achieve 98% SO 2 removal when burning low-sulfur, blended coal, while allowing future expandability to treat a higher sulfur fuel with minimal upfront cost and a modest cost of retrofit. Procurement of the Stebbins absorber vessel was excluded from ADVATECH’s scope of supply.

9

# Creating and **Preserving Value Through Project Integration** 



# Project Integration

  

   

   
 
                
    ­ 
   ­   
     
   

# 

n **Technology Provider**
Like most technology providers, ADVATECH can provide all tech nology performance requirements necessary for a customer to achieve regulatory compli

ance. Where ADV ATECH differs, however, is through optimization of technology inte

gration, allowing delivery of the lowest
cost solution.
ADVA TECH offers a full range of tech

nologies for control of NO x , SO 2 , SO 3 , PM, Hg, and HAPs. We also offer techno

logical solutions for Zero Liquid Discharge, and can optimize around any fuel and

even provide for maximum fuel flexibility. 

# n **Single-Point Responsibility EPC Contractor** 
Unlike a traditional OEM, ADVATECH’s world-class EPC capabilities provide complete, seamless project and tech

nology integration. With single-point responsibility , ADVATECH minimizes or eliminates multi-company interfaces to deliver a low-cost project. Our experienced and outstanding team provides expertise for full program and project management, conceptual and detailed design engineering, optimized procurement and quality management, direct hire or managed subcontract construction, commissioning, startup, and tuning. Through our wide ranging and demon

strated capabilities, we deliver certainty of outcome

. ADVATECH’s mission is to deliver certainty of outcome —something our
customers demand and deserve. W e believe this is best accomplished by integrating technology solutions with all other aspects of project execution.As a major EPC provider with a worldclass technology, ADV ATECH has been exceptionally successful in delivering over 14,000 MW of AQCS systems worth over $2B to the U.S. utility industry. Not only are we the lowest cost provider , we also
meet or exceed all project parameters.
ADVA TECH achieves these results by pro

viding a world-class superior portfolio of technologies, single-point EPC responsi

bility , and unique long-term services. 

# n **Long-Term Service Provider**
In addition to technology and project delivery, ADVATECH offers much more. Our unique relationship with regulatory agencies (local and national) allows us to offer advantages in permitting support and system monitoring. Our unmatched experience in process and system improvement, dating back to the 1970s, provides you with ongoing support as regulations evolve. Our unprecedented R&D efforts in the U.S. and Japan means new technologies are developed and commercialized on a regular basis, thus providing for future optimization and efficiency improvements Through these long-term services, certainty of outcome is ensured in the future.

10

### The 400-MW Single Tower DCFS Test Facility (MHI Mihara, Japan) SiC spray nozzle Pilot plants

can use a client’s coal, limestone, and makeup water to simulate desired conditions. 100 MW absorber fluid dynamics model ADVATECH, through MHI and URS, is strongly committed to research and development, and to bringing con tinuous improvements to the utility industry. We have large, modern research facilities dedicated to air pollution control.
ADVA TECH’s wet FGD system has evolved to a simple, reliable, and highly efficient single loop, double contact flow scrubber. Prominent technology improvements inlcude the single-stage DCFS spray header design and Jet Air Sparger (JAS) for gypsum oxidation. The JAS has no moving parts and is so effective at oxidation and agitation that it not only reduces oxidation air and agitator requirements, but also eliminates the need for blowers on units burning low-sulfur fuel. A full-featured, wet FGD pilot plant that can use site-specific coal, limestone, and
water sources is available to model client-specific operating conditions, and
characterize the multi -pollutants in the flue gas. Recent developments have focused on control of trace emissions such as sulfuric acid mist (H 2 SO 4 ), Hg, HCl, HF, and
sele nium. URS and MHI have developed technologies for 90 percent or greater reduction of mercury emissions. URS has significant operating experience for the control of SO 3 emissions with the use of SBS Injection TM . When treatment takes place upstream of the air heater, the acid dew point is significantly decreased, paving the way for boiler efficiency improvements.
ADVA TECH brings the full talent and capabilities of MHI and URS research and development to the U.S. market. We can design our control technologies to account for future emissions requirements, providing reassurance that you can comply with future emissions control legislation. 

# Relentless Improvement

# Corporate Strength and Commitment

ADVATECH combines the strength and corporate commitment of two world-class organizations – URS and Mitsubishi Heavy Industries – to manage, engineer, procure, and construct the optimum technology solutions for emerging environmental requirements. Over $35B in annual revenue stands behind ADVATECH, the most successful solutions provider in the industry. Washington Division 

# CERTAINTY OF OUTCOME

**For more information contact:**

George Sacco Vice President Business Development ADVATECH Atlanta, GA

Phone: 678.808.8841 Mobile: 770.335.3559 Email: george.sacco@urs.com Scott Miller Director of Engineering Technology ADVATECH Austin, TX

Phone: 512.419.5386 Mobile: 512.431.4790 Email: scott.d.miller@urs.com Naoki Kojima Vice President Commercial ADVATECH Austin, TX

Phone: 512.219.2369 Mobile: 512.815.8036 Email: naoki_kojima@mhiahq.com



# www.AdvatechLLC.com SBS Injection is a trademark of URS Corporation The information contained herein is provided for advertising and general information purposes only, and does not constitute any warranties or guarantees. Copyright © 2013 ADVATECH LLC 

# Certainty of outcome **is what ADVATECH has delivered since 2002 through:** Superior, low-cost technologies Exceptional single-point integrated EPC project execution Business structure that aligns Owner and ADVATECH goals for project delivery