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GAS ENGINES Shaw Group & the new 660MW Madison 3 power plant AIP looks at how the Shaw Group's design work has realised the Cleco Power's new US$1bn 660-MW Madison 3 power plant in the USA. As the EPC contractor Shaw has helped to bring one of the cleanest, greenest solid-fuel electric generating plants to the USA mainland. Founded in 1987, Shaw Group has grown to become a leading global provider of full-service, value-added engineering, design, procurement, construction, and maintenance services. 2010 has seen Shaw's design work come to fruition with the opening of the Cleco Power 660-MW Madison 3 power plant in the USA. As the contractor in charge of engineering, procurement and construction (EPC), Shaw has helped to construct one of the cleanest solid-fuel electric generating plants to the USA . Today it is one of the largest petroleum coke (petcoke)-fired facilities in the world to commercial operation in 2010. The new electric generation unit incorporates two 330-MW state-of-the-art circulating fluidised bed (CFB) boilers supplying steam, including reheat, to a single turbine generator. Madison 3's air quality control systems include a selective noncatalytic reduction system, scrubber and baghouse, reducing plant emissions to very low levels. Although the unit has the ability to burn 100% petcoke, it also can burn a variety of inexpensive solid fuels, avoiding the need to consume higher-cost natural gas and/or oil and resulting in savings for our client. A byproduct of oil refineries, petcoke is typically low cost and Cutaway of the plant’s boiler. CFB layout. conveniently located at source refineries in Louisiana. A closed-design pipe conveyor belt, which carries fuels from a nearby river oxbow to the site's crusher house, snakes over and around railroad crossings and highways, enabling materials to be transported safely while avoiding obstacles. Madison Unit 3 began commercial operation on February 12th, 2010 and stands as the company’s largest generating unit. Using a technology which can use multiple solid fuels to generate power, the 600MW unit will initially use petroleum coke or pet coke, a byproduct of the oil refining industry, in its boilers. However, this unique technology, circulating fluidised-bed technology, also can use biomass as fuel. Research is ongoing into the use of woody biomass as a potential fuel since the new facility is located in a timber-rich area. Biomass is a carbon-neutral fuel which will help lower the carbon footprint and serve as a renewable fuel source. In addition to the potential of lowering carbon emissions, the technology also addresses regulated emissions. Because the boiler firing temperature is about 1,600°F (871°C), nitrogen oxides (NOx) do not form. In addition, Madison 3 has installed emission control systems to the boiler that further reduce NOx. Sulphurdioxide emissions are now almost nonexistent thanks to the use of adding limestone with the fuel in the boiler and scrubbers as a post-combustion control. The new unit is estimated to use about 1.5 million tons of pet coke and 500,000 tons of limestone each year. Both the pet coke and limestone are barged to an off-loading facility located on the Red River. Built at the Brame Energy Center, the unit is 100% owned by Cleco Power LLC. The unit is the utility’s first regulated generation project in more than 20 years and employs nearly 80 new workers. AIP Internet link www.shawgrp.com 18 A UTUMN 2010 • AMERICAN I NDEPENDENT P OWER
THE WORLD’S NUMBER 1 CHOICE FOR GEN-SET CONTROL # THE FUTURE OF GEN-SET SYNCHRONISING HAS ARRIVED! DSE is pleased to announce the release of two new gen-set synchronising control solutions. The DSE86xx and DSE87xx deliver single part and two-part control options for up to 32 generators. The high levels of functionality within the products and the versatility of the two-part solution combine to deliver a collection of products that will shape the future of multiple gen-set control for many years to come! DSE87xx DSE86xx Initial demand for these control modules is already extremely high. To see the extensive range of features and benefits these control modules will give your applications visit: www.deepseaplc.com DEEP SEA ELECTRONICS PLC Highfield House, Hunmanby Industrial Estate, Hunmanby, North Yorkshire YO14 0PH England TELEPHONE +44 (0)1723 890099 FACSIMILE +44 (0)1723 893303 EMAIL sales@deepseaplc.com WEBSITE www.deepseaplc.com 1975 – 2010
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