Two new industrial stacks for Spurlock Power Station in the USA

Large coal fired power station in Kentucky builds two industrial stacks with PennguardTM lined steel flues for FGD wet stack service.

The East Kentucky Power Cooperative (EKPC) produces electricity for 16 regional power cooperatives, which between them serve one million consumers in 89 counties. The Spurlock Power Station near Maysville, Kentucky is EKPC’s largest power station. Spurlock station has recently completed two wet limestone flue gas desulphurization (FGD) systems, each with a new, PennguardTM lined industrial stack.

The two FGD systems were fitted to the 325 MW Unit 1 (in service since 1977) and the 525 MW Unit 2 (in service since 1981). Both are conventional coal fired units, using coal with a sulphur content of 3.5 % – 4.2 %. The two FGD’s will remove some 98 % of the sulphur oxides from the exhaust gas flows of Units 1 and 2. In addition to Units 1 and 2, the Spurlock station operates two 268 MW circulating fluidized bed (CFB) boilers, which are among the cleanest coal fired units in the United States.

industrial stack - spurlock-10
Hadek QA Inspector keeping track of temperture and humidity

The addition of FGD systems to Units 1 and 2 presented EKPC with several options for the industrial stacks. Together with their consulting engineers, Stanley Consultants from Muscatine, Iowa, EKPC looked at the possibility of relining the existing Unit 2 industrial stack to make it suitable for carrying FGD treated, water saturated flue gas.
It was found however, that the fast construction and commissioning schedule of the FGD retrofit project would not allow a sufficiently long outage to achieve this.

Following a technical and economical investigation of all options, EKPC decided to award to Karrena International LLC the design and construction of two, 198 m high concrete industrial stacks, each with a single, PennguardTM lined steel flue.