One of three projects undertaken by Ameren to reduce harmful emissions from coal-fired powerplants, the installation of two new wet flue gas desulfurization scrubber systems at Ameren's Sioux Energy Center in West Alton, Mo., required more than 2.2 million man-hours and as many as 550 craftsworkers during peak periods.

Photo Courtesy of MC Industrial Inc.

Ameren's power plant is one of the first U.S. installations to incorporate Hitachi Power Systems of America's spray tower scrubber, a technology expected to reduce sulfur dioxide emissions by 95%.

Ameren's power plant is one of the first U.S. installations to incorporate Hitachi Power Systems of America's spray tower scrubber—or wet scrubber—a technology expected to reduce sulfur dioxide emissions by 95%.

Engineering and construction were performed in tandem, an approach that required early involvement of the project's mechanical and electrical contractors to facilitate early constructability reviews.

Likewise, the team contracted early with key material suppliers, such as those responsible for duct-work and fabricated steel. Due to early supplier involvement, the team also was able to lock in pricing for major commodity items such as copper wire for the duration of the project.

Among other activities, the renovation project called for replacement of inlet duct sections weighing more than 270,000 lb in order to accommodate higher pressures from new fans. Because removal and replacement of duct sections occurred above an operational plant, team members employed building information modeling to develop lifting plans that were both safe and effective. Laser scans of the plant yielded as-built models from which animation was developed to demonstrate the lift.

In all, the project called for 23,000 cu yd of concrete; 1,850 tons of reinforcing steel, 2,400 tons of structural steel and 1,800 tons of field-assembled flue gas ductwork; 70,000 linear feet of piping systems; 10 55,000-gpm slurry recycle pumps; more than 20 smaller pumps; and two processed limestone reagent storage domes with in-floor air-slide conveying systems.

Team members attribute the project's success to a collaborative effort among all stakeholders—from designers and craftsworkers to members of Ameren's top management team.

Key Players

Developer/Owner: Ameren Corp., St. Louis

GC/CM: MC Industrial Inc., St. Louis

Energy Engineer: Sargent & Lundy, Chicago

Structural Engineer: Sargent & Lundy, Chicago

M/E/P Engineer: Sargent & Lundy, Chicago

Submitted by: MC Industrial Inc.

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