Pennguard^TM linings for ducts

For new and existing ducts

Suitable for inlet, outlet and bypass ducts, both for new build and retrofits. Pennguard^TM linings are simple to apply in situ in existing ducts and offer high tolerance of surface imperfections such as pitting corrosion, weld roughness and weld porosities.

Uncomplicated to install

Unlike other linings, Pennguard^TM linings are uncomplicated to apply in existing ducts. Pennguard^TM linings offer the advantage of a low weight and a high tolerance of surface imperfections such as pitting corrosion or rough welds. Installing Pennguard^TM linings is more economical than replacing sections of existing ductwork.

No external insulation required

New ducts with a Pennguard^TM lining can be built at ground level, then easily lifted to installation height. The thermal properties of a Pennguard^TM lining make expensive external insulation unnecessary.

Pennguard^TM linings are suitable for a wide range of fuels (coal, oil, petcoke, lignite, biofuels) and operating conditions. A number of power stations worldwide that fire high sulphur fuels have gathered positive long term experience using Pennguard^TM linings in FGD outlet ducts. The operating experience shows that even under highly acidic conditions, Pennguard^TM linings offer an estimated service life of more than 30 years and require very little maintenance.

Protect FGD outlet ducts exposed to highly corrosive conditions durable and reliable with Pennguard^TM linings.
– See project: Teruel Power Station, Spain

Years of experience

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Wet Stack Design Study
Opatovice PP Play the full video

Wet Stack Design Study
Opatovice PP https://www.youtube.com/watch?v=L0NdG23g2Qk

Opatovice Power Station

Lignite fired power station renews its flue gas desulphurization system and converts its existing chimney to a Pennguard^TM lined wet stack

When a power station changes over to non-reheated FGD wet stack operation, it is very important to consider the risk of "spitting", which is the emission of droplets with acidic condensate from the top of the chimney. This risk and possible remedies, can be investigated through a Wet Stack Design Study, which models the behavior of droplets in the outlet ducts and industrial chimney downstream of the FGD system.

Read more
Key facts
- Lignite fired power station, 330 MWe and 650MWt
- Wet limestone FGD
- 135 m high reinforced concrete chimney with sectional brick flue
- Pennguard^TM lining applied directly onto internal surface of the brick flue
Opatovice Power Station
- Pennguard^TM lining: installed in existing chimney with brick flue
- Flue gas treatment: wet limestone FGD
- Flue gas: 60ºC desulfurized, non-reheated (wet stack)
Read more
Sadara steam station

Oil and gas fired steam station in Saudi Arabia uses Pennguard^TM lined free-standing steel chimneys downstream of its FGD systems

Weld it. Stack it. Line it. - The construction of a very large project like the Sadara chemical complex requires that each and every part is completed reliably, on time, and on budget. This rule also applies to the welding, the erection, and the lining of the six steel chimneys. Once the industrial chimneys were in place, the Pennguard^TM lining was installed in three steps.

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Key facts
- 6 x 80 MW oil and gas fired steam plant
- Alstom New Integrated Design (NID) FGD system (Semi dry)
- Six free-standing steel chimneys
- Pennguard^TM lining system installed in the steel chimneys
Sadara steam station
- Pennguard^TM lining: installed in six new steel chimneys
- Flue gas treatment: Semy-dry FGD
- Flue gas: desulfurized, non-reheated to 81˚C
Read more
Rybnik Power Station

Coal fired Power Station in Poland uses Pennguard^TM linings to protect corroded steel chimney flues while leaving old organic coating in place

To maximize efficiency of the FGD plants, the owner decided to operate wet stack. To protect the steel flues of the industrial chimney against corrosion, they were both lined with a sprayable organic coating. The coating appeared not to be fully resistant to the demanding environment. In 2012 and 2013 Rybnik repaired both flues by installing Pennguard^TM linings directly over the existing coating, avoiding costly and time consuming repairs.

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Key facts
- 1,775 MW coal fired power station
- Two wet FGD plants for four 215 MW units
- 120 m high FGD wet stack with two steel flues
- Pennguard^TM lining applied directly onto organic lining inside corroded chimney flues
Rybnik Power Station
Pennguard^TM lining: installation in existing concrete chimney in two steel flues

Flue gas treatment: wet limestone FGD

Flue gas: desulfurized, non-reheated 52°C (wet stack)

Read more
Amercentrale power station unit 9

Large coal-fired power station increases its efficiency by eliminating flue gas reheat and converting its industrial chimney to a Pennguard^TM lined wet stack

After some 20 years of operation, the steam reheater of Amercentrale 9 had come to an end. The owner then considered the options of replacing the reheater, or converting the chimney to a ‘wet stack’. Not operating a reheater would deliver a significant increase in overall power plant efficiency. Also, sealing the brick flue with Pennguard^TM was achievable within the already scheduled 31-day outage.

Read more
Key facts
- 640 MW coal-fired power station
- Wet limestone FGD
- 181 m high reinforced concrete industrial chimney with sectional brick flue
- Pennguard^TM lining applied directly onto the brick flue’s internal surface in two phases
Amercentrale power station unit 9
Pennguard^TM lining: installation in existing concrete chimney with one sectional brick flue

Flue gas treatment: wet limestone FGD

Flue gas: desulfurized, non-reheated 50-55°C

Read more
Hongsa Power Station

Very large mine mouth, lignite fired power station in Laos uses Wet Limestone FGD and industrial chimney with Pennguard^TM lined steel flues

Just across the border of Northern Thailand, a consortium of two Thai companies, Banpu Power and Ratchaburi Electricity, along with the Lao Government are constructing one of the world’s largest new mine mouth power stations. The mild steel chimney flues were protected with 18,263 m² of Pennguard^TM linings to a high quality standard, on schedule and under challenging conditions. How?

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Key facts
- 3 x 626 MW lignite fired power station
- Wet Limestone FGD system with GGH reheat
- 250 m high reinforced concrete industrial chimney
- Three Pennguard^TM lined steel chimney flues
Hongsa Power Station
- Pennguard^TM lining: installation in new concrete chimney with three steel flues
- Flue gas treatment: wet limestone FGD
- Flue gas: desulfurized, reheated 81-84°C
Read more
Medupi and Kusile power stations

Two 4800 MW, newly built coal fired power stations in South Africa use industrial chimneys with Pennguard^TM lined steel flues

State electricity producer Eskom decided to construct two new 4800 MW coal fired Medupi and Kusile power stations to secure the power supply in South Africa. All twelve steel chimney flues were protected with Pennguard^TM linings. Two experts from TÜV Rheinland visited the Kusile site to perform a safety audit during a large scale Pennguard^TM installation over a period of several days. Is it safe?

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Key facts
- Two 6 x 800 MW coal-fired power stations
- FGD to be retrofitted to Medupi Power Station
- Wet limestone FGD, no reheat for Kusile Power Station
- Two, 220m-high reinforced concrete chimneys for each station
- Three Pennguard^TM- lined steel flues in each chimney
Medupi Power Station
- Pennguard^TM lining: installed in two concrete chimneys each with three steel flues
- flue gas treatment: wet limestone FGD
- Flue gas: initially non FGD, followed by desulfurized, non-reheated flue gas 52°C (wet stack)
Read more
Kusile Power Station
- Pennguard^TM lining: installation in new concrete chimneys with three steel flues
- flue gas treatment: wet limestone FGD
- Flue gas: desulfurized,non-reheated 48-52°C (wet stack)
Read more
Elektrowni Dolna Odra Unit 5-8

Coal fired power station in Poland modifies existing chimney for FGD wet stack operation by installing Pennguard^TM lining onto concrete windshield

To make the industrial chimney suitable for wet stack operation, the contractor has removed the brick flue and its supports, and then installed a Pennguard^TM lining directly onto the concrete windshield. This design change results in a chimney top diameter of 12.6 m and a very safe gas flow velocity of ca. 11 m/s. No spitting is expected at this low gas velocity. This Project Report shows the modification step-by-step.

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Key facts
- Unit 5 - 8 (2 x 222 MW and 2 x 232 MW) use a single industrial chimney
- Since 2002: FGD with reheat for Unit 7 & 8
- After 2012: FGD for all Units, no reheat
Elektrowni Dolna Odra Unit 5-8
- Pennguard^TM lining: installation in existing concrete shell directly
- Flue gas treatment: wet limestone FGD
- Flue gas: desulfurized, non-reheated 49°C
Read more
Pecém and Itaqui power stations

Three new coal fired power stations in Brazil use New Chimney Design^TM to minimize chimney construction cost and maximize long term reliability

MPX Energia constructed three coal fired thermal power plants (TPPs) in Brazil with semi dry scrubbers to reduce SO₂. The 67ºC scrubbed flue gas temperature, is well below the sulphuric acid dewpoint. Consequently, the internal surfaces of the industrial chimneys must be resistant to sulphuric acid condensate. The owner chose New Chimney Design (NCD) chimneys, to achieve both low construction cost and long term durability.

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Key facts
- Pecém I: 2 x 360 MW power station Pecém II: 1 x 360 MW power station Itaqui: 1 x 360 MW power station
- Semi dry FGD for SO₂ reduction
- Flue gas temperature 67 °C
- Four Pennguard^TM lined concrete chimneys (New Chimney Design)
Porto do Pecem Power Station
- Pennguard^TM lining: installation in new concrete chimneys, on concrete shell directly (New Chimney Design).
- Flue gas treatment: Semi dry FGD
- Flue gas: desulfurized, non-reheated 67°C
Read more
Porto do Itaqui Power Station
- Pennguard^TM lining: installation in new concrete chimney, on concrete shell directly (New Chimney Design).
- Flue gas treatment: Semi dry FGD
- Flue gas: desulfurized, non-reheated 67°C
Read more
Patnow Power Station

Large power station in Poland saves money, time and space by using the New Chimney Design for two new FGD wet stacks

As the existing chimneys were not suitable for wet stack operation, the owner decided to construct two Pennguard^TM lined concrete chimneys (New Chimney Design). Even though two industrial chimneys seemed more expensive than one twin flue chimney, the cost of two chimneys could be kept low, by applying the Pennguard^TM lining directly to a slender concrete shell, avoiding the use of internal flues.

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Key facts
- 4 x 200 MW lignite fired units
- Two wet limestone FGD systems
- No flue gas reheat
- Each FGD absorber is connected to a Pennguard^TM lined concrete chimney (New Chimney Design)
Patnow Power Station Unit 1-4
- Pennguard^TM lining: installed in 2 new concrete chimneys, on concrete shell directly (New Chimney Design).
- Flue gas treatment: wet limestone FGD.
- Flue gas: desulfurized, non-reheated 67°C (wet stack).
Read more
Patnow II Power Station
Pennguard^TM lining: in existing chimney with sectional brick flue

Flue gas treatment: wet limestone FGD

Flue gas: desulfurized, non-reheated 67°C
Tanjung Bin Power Station

Large new coal fired power station in Malaysia uses Pennguard^TM lining system for protection of its three steel chimney flues

To protect the steel chimney flues against the very corrosive and variable operating regime, Pennguard^TM linings were applied over their full height. In total, the three steel chimney flues use 13,037 m2 of Pennguard^TM linings. The builders of the Tanjung Bin chimney (BEC) chose for pre-lined cans and bolted flanges.

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Key facts
- 3 x 700 MW coal fired power station
- Sea Water FGD on all three units
- Partial FGD bypass
- 200 m reinforced concrete chimney with three, Pennguard^TM lined steel flues
Tanjung Bin Power Station
- Pennguard^TM lining: installed in 3 new FRP outlet ducts
- Flue gas treatment: sea water FGD / bypass reheat
- Flue gas: desulfurized, reheated, mix of scrubbed 36°C and unscrubbed 160°C
Tanjung Bin Power Station
- Pennguard^TM lining: installed in new concrete chimney with 3 steel flues
- Flue gas treatment: sea water FGD / bypass reheat
- Flue gas: desulfurized, reheated 75°C, FGD bypass 137°C
Read more
Tanjung Jati B Power Station
- Pennguard^TM lining: in new concrete chimney with two steel flues
- Flue gas treatment: wet limestone FGD
- Flue gas: desulfurized, reheated 53 - 80˚C
Tanjung Bin 4 Power Station
- Pennguard^TM lining: installation in new concrete chimney with one steel flue
- Flue gas treatment: sea water FGD
- Flue gas: desulfurized, reheated 75°C
Colbun and Bocamina Power Stations

Two new coal fired power stations in Chile use New Chimney Design and find their industrial chimneys undamaged after strong earthquake

Both Colbun and Bocamina power stations have ‘New Chimney Design’ (NCD) chimneys, protected by lightweight, insulating Pennguard^TM linings applied directly to its inside concrete surface. NCD chimneys are lighter than conventional chimneys with internal flues. This makes the design safer during earthquakes. This Project Report describes the NCD chimneys in strong earthquakes in theory and in practice.

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Key facts
- 1 x 370 MW coal fired power stations
- FGD for SO₂ reduction
- Flue gas reheated to 60 - 80 °C
- Pennguard^TM lined concrete chimneys (New Chimney Design)
Colbun Power Station
- Pennguard^TM lining: installation in new concrete chimney, on concrete shell directly (New Chimney Design)
- Flue gas treatment: sea water FGD
- Flue gas: desulfurized, reheated 60°C
Read more
Bocamina II Power Station
- Pennguard^TM lining: installation in new concrete chimney, on concrete shell directly (New Chimney Design)
- Flue gas treatment: wet limestone FGD
- Flue gas: desulfurized, reheated 80°C
Read more
Rovinari power station

Lignite fired power station in Romania fits FGD with Wet Booster Fans and Pennguard^TM lined concrete chimneys for maximum efficiency

One significant decision was to place the required booster fans downstream, rather than upstream of the FGD absorbers. The second decision was to use Pennguard^TM lined concrete chimneys (New Chimney Design), to lower the construction cost compared to traditional chimneys and to minimize the condensate formation within the wet stacks.

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Key facts
- 4 x 330 MW lignite fired power station
- Wet limestone FGD with Wet Booster Fan for Units 3 - 6
- No flue gas reheat
- Four Pennguard^TM lined concrete chimneys (New Chimney Design)
Rovinari power station
- Pennguard^TM lining: installation in four new concrete chimneys, on concrete shell directly (New Chimney Design)
- Flue gas treatment: wet limestone FGD
- Flue gas: desulfurized, non-reheated 62°C (wet stack)
Read more
Quang Ninh Power Plant

New 4 x 300 MW coal fired power station in Vietnam uses FGD chimneys with Pennguard^TM lined steel flues

Owners expect near 100% availability from every component of their plant, including the industrial chimney lining. The steel flues of the two Quang Ninh Power Station chimneys have been lined with 331,200 pieces of Pennguard^TM Block. To meet the owner’s expectations, the production, engineering and installation of the Pennguard^TM lining system followed a rigorous step-by-step quality control process.

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Key facts
- 4 x 300 MW coal fired power station
- Wet limestone FGD
- Reheat by rotating gas-to-gas heaters
- 2 concrete chimneys each with two Pennguard^TM lined steel flues
Quang Ninh I Thermal Power Plant
- Pennguard^TM lining: new chimney with two steel flues
- Flue gas treatment: wet limestone FGD
- Flue gas: desulfurized, reheated to 80°C
Read more
Quang Ninh II Thermal Power Plant
- Pennguard^TM lining: installation in new concrete chimney with two steel flues.
- Flue gas treatment: wet limestone FGD.
- Flue gas: desulfurized, reheated to 80°C.
Read more
Spurlock Power Station

Large coal fired power station in Kentucky builds two industrial chimneys with Pennguard^TM 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 completed two wet limestone flue gas desulphurization (FGD) systems, each with a new, Pennguard^TM lined chimney.

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Key facts
- 1 x 325 MW, 1 x 525 MW and 2 x 268 MW coal fired power station
- Wet limestone FGD on Unit 1 and Unit 2
- No flue gas reheat
- Two new concrete chimneys with a Pennguard^TM lined steel flue
Spurlock Power Station Unit 1 and 2
- Pennguard^TM lining: in 2 new concrete chimneys with a steel flue
- Flue gas treatment: wet limestone FGD
- Flue gas: desulfurized, non-reheated 52°C (wet stack)
Read more
Castle Peak B Power Station Unit 1 – 4

Largest coal fired power station in Hong Kong fits FGD and installs Pennguard^TM linings in 250 m high chimney with four flues

Due to the FGD retrofit, the flue gas temperature would drop well below its acid dewpoint, resulting the need to protect the unprotected steel flues with a chimney flue lining system. CLP Power decided to install Pennguard^TM linings within scheduled outage times only. More than just being quick, the work would have to result in a lining service life exceeding 20 years, without significant maintenance or repair.

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Key facts
- 4 x 677 MW coal fired boilers
- FGD for SO₂ reduction
- Flue gas reheated to 80°C
- Pennguard^TM linings installed in existing 250 m industrial chimney with 4 steel flues
Castle Peak B Power Station Unit 1 – 4
- Pennguard^TM lining: installation in existing concrete chimney with 4 steel flues
- Flue gas treatment: wet limestone FGD
- Flue gas: desulfurized, reheated 80°C, FGD bypass 150°C
Read more
San Juan Generating Station

Coal fired power station in the western United States prepares its four industrial chimneys for wet stack operation by installing Pennguard^TM linings in the brick flues

Ever since the introduction of FGD plants, owners have decided to re-use their existing, brick lined chimneys for low temperature, acid condensing operation. Brick flues have been prepared for aggressive FGD operating conditions in various ways and Pennguard^TM linings have proven to be the most effective, durable technology. Why?

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Key facts
- 2 x 350 MW and 2 x 550 MW coal fired power station
- wet FGD on all four units
- No flue gas reheat
- All four existing chimneys with brick flues to be lined with Pennguard^TM
San Juan Generating Station Unit 1 and 2
- Pennguard^TM lining: installed autumn 2008/ spring 2009 in 2 existing concrete chimneys with brick liner
- Flue gas treatment: wet limestone FGD
- Flue gas: desulfurized, non-reheated 52°C (wet stack)
Read more
San Juan Generating Station Unit 3 and 4
- Pennguard^TM lining: installed in 2 existing chimneys with brick liner
- Flue gas treatment: wet limestone FGD
- Flue gas: desulfurized, non-reheated 52°C (wet stack)
Read more
Aberthaw Power Station

Coal fired power station in Wales prepares existing chimney for FGD operation by installing Pennguard^TM linings in brick flues

RWE npower decided to fit Sea Water Flue Gas Desulfurization (FGD) at Aberthaw power station based on more stringent SO₂ emissions regulations. This would have consequence for the existing 40 year old brick flue chimney. This Project Report describes the industrial chimney modification process in a step-by-step process and explains in detail how a Pennguard^TM lining protects a brick flue from thermal stress.

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Key facts
- 3 x 500 MW coal fired power station
- Seawater FGD
- 153 m concrete chimney with 3 sectional brick flues
- Pennguard^TM lining directly applied onto the brick flues for safe wet stack operation
Aberthaw Power Station
- Pennguard^TM lining: installed in existing chimney with 3 brick liners
- Flue gas treatment: sea water FGD
- Flue gas: desulfurized, reheated 50°C, FGD bypass 130°C
Read more
Cottam Power Station

British coal-fired power station uses Pennguard^TM linings to prepare its existing multi-flue chimney for wet stack operation

For environmentally safe operation of the wet stack, EDF Energy contracted Alden Research Laboratory, to study the options for the outlet ducts and the industrial chimney flues. Based on the consultant’s recommendations, the existing chimney was modified by removing the brick linings from the 4 concrete flues and by protecting the inner concrete surface with Pennguard^TM linings directly. How? Click on read more.

Read more
Key facts
- 4 x 500 MW coal fired power station
- Wet FGD fitted to all 4 units
- No flue gas reheat
- Existing 4-flue chimney modified for wet stack use
- Brick removed, Pennguard^TM lining applied to concrete flues
Cottam Power Station
- Pennguard^TM lining: installed in 4 existing concrete chimneys each with 4 concrete flues
- Flue gas treatment: wet limestone FGD
- Flue gas: desulfurized, non-reheated 50°C (wet stack)
Read more
Coleson Cove Generating Station

Canadian power station fits FGD for 25 more years of service and constructs a new chimney with Pennguard^TM lined flues

To convert Coleson Cove station into a low cost generator, NB Power decided to make the station suitable for firing Orimulsion and to operate wet stack. For this, a new chimney with two Pennguard^TM lined steel flues was constructed. The Project Report also describes how insulating Pennguard^TM linings will help to reduce condensate formation within wet stacks during start-ups.

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Key facts
- 3 x 350 MW heavy fuel oil fired power station
- Wet FGD and wet precipitator
- 182 m concrete chimney with two Pennguard^TM lined steel flues
- Pennguard^TM linings help to reduce condensate formation during start-ups
Coleson Cove Generating Station
- Pennguard^TM lining: installed in new concrete chimney with 2 steel chimney flues
- Flue gas treatment: wet FGD and wet precipitator
- Flue gas: desulfurized, non-reheated 57°C (wet stack)
Read more
Craiova Power Station

Romanian power station modifies concrete chimney using Pennguard^TM Block Lining System

A technical survey of the chimney showed that the concrete shell and the brick lining supports were under attack from sulphuric acid condensate. Also, thermal cycling had created wide cracks in the concrete windshield. Any further deterioration of the industrial chimney would be an unacceptable risk, also considering the earthquake risk. This Project Report describes the chimney refurbishment project.

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Key facts
- 400 MW coal fired power station
- Coal with 8 – 12% sulfur
- Unscrubbed flue gas 140 – 160 ºC
- Modification of 200 m high concrete chimney with brick liner
- Brick liner removed and Pennguard^TM linings installed onto concrete shell
Craiova Power Station
- Pennguard^TM lining: installed in existing chimney on concrete shell
- Flue gas treatment: no FGD at present time
- Flue gas: unscrubbed 140 - 160°C
Read more
West Burton Power Station

Large coal fired power station in England uses Pennguard^TM linings for its new FGD chimneys

An increasing number of coal fired power stations are experiencing frequent start-ups and shutdowns as they have to follow the demands of a free electricity market. West Burton Power Station is a good example; outside of the winter season, it often operates on a “two-shift” schedule, starting its 500 MW units every morning and stopping them every night. This cycling operating schedule creates many challenges for the station.

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Key facts
- Pennguard^TM lining: installed in 2 new concrete chimneys with each 2 steel flues
- Flue gas treatment: wet FGD with gas-gas-reheat
- Flue gas: desulfurized, reheated 88°C
West Burton Power Station
- Pennguard^TM lining: installed in 2 new concrete chimneys with each 2 steel flues
- Flue gas treatment: wet FGD with gas-gas-reheat
- Flue gas: desulfurized, reheated 88°C
Read more
Hadong Power Station

South Korean Power Station installs Pennguard^TM linings to prepare six concrete chimneys for FGD operation

Before the introduction of FGD, the standard chimney design for KEPCO’s coal fired power stations was a 150m high concrete chimney, protected internally with a sectional ceramic brick liner. The addition of FGD absorbers to all six units would create a technical problem for the old chimney design. The customer chose Pennguard^TM linings in 6 concrete industrial chimneys in 3 different ways.

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Key facts
- 6 x 500 MW coal fired power station, South Korea
- Wet FGD with gas-gas-reheater for all units
- Modification of six 150 m high concrete chimneys
- Pennguard^TM linings applied directly onto brick and concrete substrates
Hadong Power Station 1 and 2
- Pennguard^TM lining: installed in two existing concrete chimneys with brick chimney liner.
- Flue gas treatment: wet FGD with gas-gas-reheat.
- Flue gas: desulfurized, reheated 85°C
Read more
Hadong Power Station 3 and 4
- Pennguard^TM lining: installed in two new concrete chimneys with Pennguard^TM on concrete
- Flue gas treatment: wet FGD with gas-gas-reheat
- Flue gas: desulfurized, reheated 85°C
Read more
Hadong Power Station 5 and 6
- Pennguard^TM lining: installed in 2 new chimneys, directly onto concrete shell
- Flue gas treatment: wet FGD with gas-gas-reheat
- Flue gas: desulfurized, reheated 85°C
Read more
Pha-Lai 2 Power Station

Vietnam’s most modern coal fired power station uses Pennguard^TM chimney flue linings

For the 200m high reinforced concrete chimney with two 4.5m diameter steel flues, the contractor decided to line the 7.2m high steel cans with Pennguard^TM on ground level first. Then, the pre-lined cans were placed inside the industrial chimney and welded to the flue. The chosen work method proved to be fast and efficient. The Pennguard^TM lined flues were installed within 8 weeks.

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Key facts
- 2 x 300 MW Power Station, Vietnam
- 0,5 – 0,7% sulphur antracite coal
- Wet FGD with 15% bypass
- 200 m concrete chimney with two Pennguard^TM lined steel flues
- Successful lining installation in tropical climate with high humidity
Pha-Lai 2 Power Station
- Pennguard^TM lining: installed in new concrete chimney with 2 steel chimney flues
- Flue gas treatment: wet FGD with 15% bypass
- Flue gas: desulfurized, reheated 60°C
Read more
Teruel Power Station

Pennguard^TM linings protect the FGD outlet ducts of a lignite fired power station

The FGD outlet ducts are exposed to highly corrosive operating conditions and sometimes to a total or partial FGD bypass of the unscrubbed gas stream. The Pennguard^TM Block Lining System was chosen for the internal protection of the three large FGD outlet ducts. After mounting the three large outlet ducts onto their support construction, the Pennguard^TM lining installation followed.

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Key facts
- 3 x 350 MW high sulfur lignite fired plant, Spain
- Wet FGD with hot air reheat to 75 – 85 ºC
- 3 steel outlet ducts, Pennguard^TM lined
Teruel Power Plant
- Pennguard^TM lining: installed in 3 new steel outlet ducts
- Flue gas treatment: wet FGD with hot air reheat
- Flue gas: desulfurized, reheated 85 °C
Read more
Sual Power Station

Pennguard^TM protects the steel chimney flues of the largest coal fired power station in the Philippines

During the selection of a suitable lining for the steel chimney flues, it became clear that the Sual project presented several specific challenges. The main points of consideration were the chemical environment in the flues, the seismic activity of the region and the adverse local climate conditions.

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Key facts
- 2 x 609 MW coal fired power station, Philippines
- Wet FGD with 30% bypass operation
- New concrete chimney with two Pennguard^TM lined steel flues
- Plant located in seismically active region
Sual Power Station
- Pennguard^TM lining: installed in new concrete chimney with two steel chimney liners
- Flue gas treatment: wet FGD with 30% bypass
- Flue gas: desulfurized, reheated 74 – 80 °C
Read more
Amercentrale, Unit 9

Pennguard^TM seals and protects leaking brick chimney liner

In 1996, it was discovered that the lower part of the internal brick liner of the Unit 9 industrial chimney was under attack by highly acidic flue gas condensate. This condensate was permeating the brick liner and threatening to attack the concrete support structure. An impermeable Pennguard^TM lining was installed directly onto the brick flue surface to prevent further leaking. Click on Read More, for details.

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Key facts
- 1 x 645 Mw coal fired power station
- Wet FGD with reheat
- 181 m high chimney with sectional brick flue
- Lower part brick flue under acid condensate attack, therefore sealed with Pennguard^TM linings
Amercentrale, Unit 9
Pennguard^TM lining: concrete chimney with one sectional brick flue

Flue gas treatment: wet limestone FGD with gas fired reheater

Flue gas: desulfurized, reheated 60°C

Read more (1996)
Dunamenti Power Station

Pennguard^TM protects steel chimney liners in a heavy oil fired power plant

6 x 220 MW heavy oil fired Dunamenti Power Station had a problem in its industrial chimneys. The station had two 200m high chimneys, each with three internal steel flues. Even though the gas temperature was 150 – 160°C, the steel flues were under strong acid attack, especially around ‘cold spots’. In order to solve the problem, the steel flues were repaired and partially relined with the Pennguard^TM Block Lining System.

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Key facts
- 9 x 220 MW power station
- Heavy fuel oil firing
- Unscrubbed flue gas 150 – 160 ºC
- Three 200 m high concrete chimneys each with 3 steel flues
- Problems and solution for cold spots
Dunamenti Power Station
- Pennguard^TM lining: installed in 3 existing concrete chimneys each with three steel chimney flues
- Flue gas treatment: no flue gas treatment
- Flue gas: unscrubbed 160°C
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Taichung Power Station 1 - 8
- Pennguard^TM lining: installed in new steel FGD ducts
- Flue gas treatment: wet FGD
- Flue gas: desulfurized, non-reheated 50°C
Petersburg Power Station Units 1 & 2
- Pennguard^TM lining: installed in new steel FGD inlet and outlet ducts
- Flue gas treatment: wet FGD
- Flue gas: unscrubbed 140°C, desulfurized, non-reheated 50°C
Petersburg Power Station Unit 1
- Pennguard^TM lining: installed in existing concrete bypass chimney with steel flue
- Flue gas treatment: wet FGD
- Flue gas: unscrubbed 140°C
Amercentrale, Unit 8
- Pennguard^TM lining: installed in existing steel FGD outlet duct
- Flue gas treatment: wet FGD with gas fired reheat
- Flue gas: desulfurized, reheated 60°C
Centrale de Cordemais, 4 and 5
- Pennguard^TM lining: installed in new steel duct
- Flue gas treatment: wet FGD with gas-gas-reheat
- Flue gas: unscrubbed 130°C – 150°C
Centrale du Havre, Unit 4
- Pennguard^TM lining: installed in new steel duct (hot side)
- Flue gas treatment: wet FGD with gas-gas-reheat
- Flue gas: unscrubbed 130°C – 150°C
Boryung Power Station 3 to 6
- Pennguard^TM lining: installed in 4 existing concrete chimneys with brick liner
- Flue gas treatment: wet FGD with gas-gas-reheat
- Flue gas: desulfurized, reheated 85°C
Taean Power Station 1 to 4
- Pennguard^TM lining: 4 existing concrete chimneys with internal brick liner
- Flue gas treatment: wet FGD with gas-gas-reheat
- Flue gas: desulfurized, reheated 85°C
Teruel Power Station Unit 1,2 and 3
- Pennguard^TM lining: installed in lower 51 m of existing single brick chimney liner
- Flue gas treatment: wet FGD with hot air reheat
- Flue gas: desulfurized, reheated 75 - 85°C
Ho-Ping Power Station
- Pennguard^TM lining: installed in new concrete chimney with 2 steel flues
- Flue gas treatment: wet FGD with gas-gas-reheat
- Flue gas: desulfurized, reheated 90°C
Samchonpo Power Station 1 - 4
- Pennguard^TM lining: installed in 2 existing steel chimneys with 4 steel flues each
- Flue gas treatment: wet FGD with gas-gas-reheat
- Flue gas: desulfurized, reheated 85°C
Vasilikos Phase II, Unit 3
- Pennguard^TM lining: installed in new concrete chimney with 3 steel flues
- Flue gas treatment: sea water FGD / GGH reheat
- Flue gas: desulfurized, reheated 84°C
Craig Generating Station 2
- Pennguard^TM lining: installation in existing concrete chimney with free
- standing brick liner (upper 75 %)
- Flue gas treatment: wet limestone FGD
- Flue gas: desulfurized, non-reheated 48°C
Tanners Creek Unit 4
- Pennguard^TM lining: installed in existing freestanding steel chimney
- Flue gas: unscrubbed 155°C
Uong Bi Power Station
- Pennguard^TM lining: installed in new concrete chimney with 1 steel flue
- Flue gas treatment: wet FGD with partial bypass
- Flue gas: desulfurized, reheated 60°C
KW Weisweiler Block G/H
- Pennguard^TM lining: installed in existing chimney with 1 brick flue
- Flue gas treatment: combined cycle
- Flue gas: unscrubbed 98°C, up to 160°C
Dallmann Power Station
- Pennguard^TM lining: installed in existing chimney with brick liner
- Flue gas treatment: wet limestone FGD
- Flue gas: desulfurized, non-reheated 50°C (wet stack)
Killen Station Unit 2
- Pennguard^TM lining: installed in existing chimney with brick liner
- Flue gas treatment: wet limestone FGD
- Flue gas: desulfurized, non-reheated 50°C, FGD bypass 139°C (wet stack)
Killen Station Unit 2
- Pennguard^TM lining: installed in existing steel bypass duct
- Flue gas treatment: wet limestone FGD
- Flue gas: desulfurized, non-reheated 50°C, FGD bypass 139°C
Marshall Steam Station Unit 1, 2, 3 and 4
- Pennguard^TM lining: installed in new steel ductwork
- Flue gas treatment: wet limestone FGD
- Flue gas: mix of 5% air and unscrubbed flue gas of 138°C (open-bypass system)
Mitchell Power Station
- Pennguard^TM lining: installed in new steel FGD outlet and chimney breeching ducts
- Flue gas treatment: wet limestone FGD
- Flue gas: desulfurized, non-reheated 52°C
Maritsa East 2 Power Station Unit 7 & 8
- Pennguard^TM lining: installed in existing chimney with concrete / brick liner
- Flue gas treatment: wet limestone FGD
- Flue gas: desulfurized, non-reheated 73°C, emergency bypass 160°C (wet stack)
Rabigh Power and Desalination Plant
- Pennguard^TM lining: installed in 3 new steel chimneys
- Flue gas treatment: wet limestone FGD
- Flue gas: desulfurized, non-reheated 58°C, emergency bypass 163°C (wet stack)
Rabigh Power and Desalination Plant
- Pennguard^TM lining: installed in new steel inlet ducts
- Flue gas treatment: wet limestone FGD
- Flue gas: desulfurized, non-reheated 58°C
Jimah Power Station
- Pennguard^TM lining: installed in new concrete chimney with 2 steel chimney flues
- Flue gas treatment: sea water FGD / bypass reheat.
- Flue gas: desulfurized, reheated 75°C, FGD bypass 140°C
Zimmer Generating Station
- Pennguard^TM lining: installed in existing concrete chimney with free standing brick liner
- Flue gas treatment: wet limestone FGD
- Flue gas: desulfurized, reheated 57°C
Kilroot Power Station
- Pennguard^TM lining: installed in existing concrete chimney with 2 steel flues
- Flue gas treatment: sea water FGD / GGH reheat
- Flue gas: desulfurized, reheated 57°C, emergency bypass 155°C
Kilroot Power Station
- Pennguard^TM lining: installed in 2 existing steel outlet ducts
- Flue gas treatment: sea water FGD / GGH reheat
- Flue gas: desulfurized, reheated 50 - 80°C / emergency bypass 155°C
Fiddler’s Ferry Power Station Units 2,3 and 4
- Pennguard^TM lining: installed in 3 existing brick lined concrete flues within a 4-flue chimney
- Flue gas treatment: wet limestone FGD with gas-gas-reheat
- Flue gas: desulfurized, reheated 82°C, FGD bypass 130°C
Ferrybridge Power Station Units 3 and 4
- Pennguard^TM lining: installed in existing concrete chimney with brick liner
- Flue gas treatment: wet limestone FGD with gas-gas-reheat
- Flue gas: desulfurized, reheated 82°C, FGD bypass 130°C
Rugeley Power Station
- Pennguard^TM lining: installed in new concrete chimney with 2 steel flues
- Flue gas treatment: wet limestone FGD with gas-gas-reheat
- Flue gas: desulfurized, reheated 80-90°C, FGD bypass 130°C
Plant Hammond Unit 1, 2, 3 and 4
- Pennguard^TM lining: installed in new steel ductwork between electrostatic precipitators and FGD absorber
- Flue gas treatment: wet limestone FGD
- Flue gas: mix of 5% air and unscrubbed flue gas of 140°C (open-bypass system)
Centrale de Provence Unit 5
- Pennguard^TM lining: installed in new steel ductwork between scrubber and chimney
- Flue gas treatment: wet limestone FGD
- Flue gas: desulfurized, non-reheated 50°C
Mondi Packaging Paper Mill
- Pennguard^TM lining: installation in new concrete chimney, directly onto concrete shell (New Chimney Design)
- Flue gas treatment: no FGD
- Flue gas: unscrubbed 140°C
Haiphong I Thermal Power Plant
- Pennguard^TM lining: installed in new concrete chimney with 2 steel flues
- Flue gas treatment: wet limestone FGD with partial bypass
- Flue gas: desulfurized, reheated 60°C
Mayo Generating Station Unit 1
- Pennguard^TM lining: installation spring 2008, in new concrete chimney with steel chimney flue
- Flue gas treatment: wet limestone FGD
- Flue gas: desulfurized, non-reheated 52°C (wet stack)
Mayo Generating Station Unit 1
- Pennguard^TM lining: installed in new steel outlet duct
- Flue gas treatment: wet limestone FGD
- Flue gas: desulfurized, non-reheated 52°C
Amos Power Station Unit 1, 2 and 3
- Pennguard^TM lining: installed in new steel FGD outlet and chimney inlet ducts
- Flue gas treatment: wet limestone FGD
- Flue gas: desulfurized, non-reheated 52°C
Oak Grove Generating Station Unit 1 and 2
- Pennguard^TM lining: installed in 2 new concrete chimneys with a steel chimney flue
- Flue gas treatment: wet limestone FGD
- Flue gas: desulfurized, non-reheated 60°C (wet stack)
Jimah Power Station
- Pennguard^TM lining: installed in 2 new FRP outlet ducts
- Flue gas treatment: sea water FGD / bypass reheat
- Flue gas: mix of desulfurized 36°C flue gas and max. 160°C untreated flue gas
Guacolda Power Station, Unit 3
- Pennguard^TM lining:In a concrete chimney, on concrete shell directly (New Chimney Design)
- Flue gas treatment: wet limestone FGD
- Flue gas: desulfurized, non-reheated 55°C
Nueva Vantanas Power Station Unit 3
- Pennguard^TM lining: installed in concrete chimney, on concrete shell directly (New Chimney Design)
- Flue gas treatment: semi dry FGD
- Flue gas: desulfurized, non-reheated 90°C
Cholla Generating Station, Unit 4
- Pennguard^TM lining: installed in existing concrete chimney with brick liner
- Flue gas treatment: wet FGD
- Flue gas: desulfurized, non-reheated 50°C
Stanton Energy Center, Unit 1 and 2
- Pennguard^TM lining: installed in new steel outlet ductwork
- Flue gas treatment: wet FGD
- Flue gas: desulfurized, non-reheated 50°C
Oglethorpe Paper Mill
- Pennguard^TM lining: installed in existing chimney, on concrete shell directly
- Flue gas treatment: wet FGD / by-pass reheat
- Flue gas: desulfurized, reheated 90°C / unscrubbed
St. John's Power Park, Unit 1 and 2
- Pennguard^TM lining: installed in new steel outlet ductwork
- Flue gas treatment: wet FGD
- Flue gas: desulfurized, non-reheated 50°C
Fayette Station Unit 3
- Pennguard^TM lining: installation in existing chimney with free standing brick liner
- Flue gas treatment: wet limestone FGD
- Flue gas: desulfurized, non-reheated 52°C (wet stack)
Fayette Station Unit 3
- Pennguard^TM lining: installed in new steel outlet ductwork
- Flue gas treatment: wet FGD
- Flue gas: desulfurized, non-reheated 50°C
Campiche Power Station
- Pennguard^TM lining: installation in a new concrete chimney, on concrete shell directly (New Chimney Design)
- Flue gas treatment: Semi dry FGD
- Flue gas: desulfurized, non-reheated 90°C
Angamos Power Station units 1 and 2
- Pennguard^TM lining: installation in new concrete chimney, on concrete shell directly (New Chimney Design)
- Flue gas treatment: Semi dry FGD
- Flue gas: desulfurized 90°C
Yanbu Steam Power Station, Units 3 and 4
- Pennguard^TM lining: installation in new concrete chimney with a steel flue
- Flue gas treatment: wet limestone FGD on Unit 4
- Flue gas: mix of desulfurized, reheated 80°C
Guacolda Power Station, Unit 4
- Pennguard^TM lining: installation in new concrete chimney, on concrete shell directly (New Chimney Design)
- Flue gas treatment: no FGD
- Flue gas: unscrubbed 147°C
Bonanza Power Station
- Pennguard^TM lining: installation in existing freestanding brick chimney liner
- Flue gas: treatment: wet limestone FGD
- Flue gas: desulfurized, non-reheated 52°C (wet stack)
C.E.T. Sud Bucuresti Unit 1
- Pennguard^TM lining: installation in existing concrete chimney, on concrete shell directly
- Flue gas treatment: no FGD
- Flue gas: Unscrubbed 140-170°C
Stanton Energy Center Unit 1
- Pennguard^TM lining: installed in existing chimney with free standing brick liner
- Flue gas treatment: wet limestone FGD
- Flue gas: desulfurized, non-reheated 52°C (wet stack)
Uong Bi II Thermal Power Plant
- Pennguard^TM lining: installation in new concrete chimney with steel flue
- Flue gas treatment: wet limestone FGD
- Flue gas: desulfurized, non-reheated 47°C (wet stack)
R.D. Morrow Generating Station
- Pennguard^TM lining: modification of existing chimney with two free standing brick flues
- Flue gas treatment: wet limestone FGD
- Flue gas: desulfurized, non-reheated 54°C (wet stack)
Crist Unit 4, 5, 6 en 7
- Pennguard^TM lining: installed in new steel ductwork between electrostatic precipitators and FGD absorber
- Flue gas treatment: wet limestone FGD
- Flue gas: mix of 5% air and unscrubbed Flue gas: unscrubbed 140°C
Siekierki Power Station Unit 1-4
- Pennguard^TM lining: installation in new concrete chimney, on concrete shell directly (New Chimney Design)
- Flue gas treatment: Unit 1,2,3,4 non-desulfurized, Unit 2 Semi dry FGD
- Flue gas:desulfurized, and reheated 138°C
Cholla Unit 3
- Pennguard^TM lining: installation in concrete chimney with two steel flues
- Flue gas treatment: wet limestone FGD
- Flue gas: desulfurized, non-reheated 53°C (wet stack)
Big Bend Power Station Unit 4
- Pennguard^TM lining: installation in existing concrete chimney with free standing brick liner
- Flue gas treatment: wet limestone FGD
- Flue gas: desulfurized, non-reheated 52°C (wet stack)
Hardingstreet Power Station Unit 7
- Pennguard^TM lining: installation in new chimney with steel flue
- Flue gas treatment: wet limestone FGD
- Flue gas: unscrubbed 149°C
GHECO-ONE power station
- Pennguard^TM lining: in new concrete chimney with steel flue
- Flue gas treatment: sea water FGD
- Flue gas: desulfurized, reheated 80°C
Rabigh IPP
- Pennguard^TM lining: installation in new concrete chimney with two steel flues
- Flue gas treatment: sea water FGD
- Flue gas: desulfurized, reheated 80°C
Rabigh VI
- Pennguard^TM lining: installation in new concrete chimneys with two steel flues.
- Flue gas treatment: sea water FGD
- Flue gas: desulfurized, reheated 60-72°C.
Jim Bridger Power Station Unit 4
- Pennguard^TM lining: installed in existing chimney with free standing brick flue
- Flue gas treatment: wet limestone FGD
- Flue gas: desulfurized, non-reheated 52°C (wet stack)
Schahfer Generating Station
- Pennguard^TM lining: installation in existing chimney with free standing brick liner
- Flue gas treatment: wet limestone FGD
- Flue gas: desulfurized, non-reheated 54°C (wet stack)
Jorf Lasfar Power Station Unit 5 and 6
- Pennguard^TM lining: installation in new concrete chimney with two steel flues
- Flue gas treatment: sea water FGD
- Flue gas: desulfurized, reheated 129°C
Yanbu 2 Power Station
- Pennguard^TM lining: installation in new concrete chimney in one of two steel flues
- Flue gas treatment: sea water FGD
- Flue gas: desulfurized, reheated 112°C
Janamanjung 4 Power Station
- Pennguard^TM lining: installation in new concrete chimney with one steel flue
- Flue gas treatment: sea water FGD
- Flue gas: desulfurized, reheated 82 - 92°C
Craig Generating Station 1 and 2
- Pennguard^TM lining: installed in 2 existing concrete chimneys with brick liner
- Flue gas treatment: wet limestone FGD
- Flue gas: desulfurized, non-reheated 48°C (wet stack)
Vinh Tan 2 Thermal Power Plant
- Pennguard^TM lining: installation in new concrete chimney with two steel flues
- Flue gas treatment: sea water FGD
- Flue gas: desulfurized, reheated 80°C
Magnetation Pellet Plant
- Pennguard^TM lining: installation in new concrete chimney, directly onto concrete shell (New Chimney Design)
- Flue gas: unscrubbed
Cochrane Power Plant
- Pennguard^TM lining: installation in new concrete chimney, on concrete shell directly (New Chimney Design)
- Flue gas treatment: Semi dry FGD
- Flue gas: desulfurized, non-reheated to 83˚C
Jeddah South Thermal Power Plant
- Pennguard^TM lining: installation in new concrete chimney with two steel flues
- Flue gas treatment: sea water FGD
- Flue gas: desulfurized, reheated 85°C
Cilacap Phase II Power Plant
- Pennguard^TM lining: installation in new concrete chimney with one steel flue
- Flue gas treatment: sea water FGD
- Flue gas: during FGD operation 65˚C, FGD bypass 133˚C
Duyen Hai 1 Thermal Power Plant
- Pennguard^TM lining: installed in concrete chimney with two steel flues
- Flue gas treatment: sea water FGD
- Flue gas: desulfurized, reheated 70°C
Gibson Generating Station
- Pennguard^TM lining: installation in existing chimney with brick liner
- Flue gas treatment: wet limestone FGD
- Flue gas: desulfurized, none-reheated 53°C
Duyen Hai 3 Thermal Power Plant and Duyen Hai 3 Extension project
- Pennguard^TM lining: installed in concrete chimney with three steel flues
- Flue gas treatment: sea water FGD
- Flue gas: desulfurized, reheated 70°C
Shuqaiq Steam Power Plant
- Pennguard^TM lining: installation in new concrete chimney with two steel flues
- Flue gas treatment: sea water FGD
- Flue gas: desulfurized, none-reheated 85°C
Thai Bin 2 Thermal Power Plant
- Pennguard^TM lining: installation in new concrete chimney with two steel flues
- Flue gas treatment: wet limestone FGD
- Flue gas: desulfurized, reheated 67°C
Vinh Tan 4 Thermal Power Plant
- Pennguard^TM lining: installation in new concrete chimney with two steel flues
- Flue gas treatment: sea water FGD
- Flue gas: desulfurized, reheated 80°C
Janamanjung 5 Power Station
- Pennguard^TM lining: installation in new concrete chimney with one steel flues
- Flue gas treatment: sea water FGD
- Flue gas: desulfurized, reheated 82 - 92°C
Safi Power Plant
- Pennguard^TM lining: installation in new concrete chimney with two steel flues
- Flue gas treatment: sea water FGD
- Flue gas: desulfurized, reheated 95°C
Haiphong II Thermal Power Station
- Pennguard^TM lining: installation in new concrete chimney with two steel flues
- Flue gas treatment: wet limestone FGD (with partial bypass)
- Flue gas: desulfurized, reheated 80°C
Mong Duong II Power Station
- Pennguard^TM lining: installation in new concrete chimney with two steel flues
- Flue gas treatment: wet limestone FGD
- Flue gas: desulfurized, reheated 80°C
Escalante Generating Station
- Pennguard^TM lining: installation in existing chimney with free standing brick liner
- Flue gas treatment: wet limestone FGD
- Flue gas: desulfurized, non-reheated 54°C (wet stack)
PLTU Keban Agung Power Station
- Pennguard^TM lining: installation in new concrete chimney, on concrete shell directly ( New Chimney Design)
- Flue gas treatment: no FGD
- Flue gas: unscrubbed 130°C
East Bend Generating Station
- Pennguard^TM lining: installation in existing chimney with free standing brick liner
- Flue gas treatment: wet FGD
- Flue gas: desulfurized, non-reheated 52°C (wet stack)
Elektrarna Tusimice II
- Pennguard^TM lining: installed in existing steel duct between GGH and scrubber (hot side)
- Flue gas treatment: wet FGD with gas-gas-reheat
- Flue gas: unscrubbed 130°C – 140°C
Mae Moh PP Unit 4 - 7 Replacement
- Pennguard^TM lining: installed in new concrete chimney with one steel flue
- Flue gas treatment: wet limestone FGD
- Flue gas: desulfurized, reheated 91ºC, FGD bypass 152ºC
Pagbilao Power Plant Extension
- Pennguard^TM lining: installed in new concrete chimney with one steel flue
- Flue gas treatment: sea water FGD
- Flue gas: desulfurized, reheated 105ºC, FGD bypass 170ºC
Jimah East Power CFPP
- Pennguard^TM lining: installed in new concrete chimney with two steel flues
- Flue gas treatment: sea water FGD
- Flue gas: desulfurized, reheated 90ºC, FGD bypass possible