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Environmental Equipment Investments

Major projects at Dairyland’s two largest power plants are benefitting regional air quality

Baghouse at Dairyland's Alma Site

Major environmental equipment installations at Dairyland’s coal-fired power plants include the "baghouse" pictured in the foreground of this photograph of the JPM plant site. Baghouses at the Genoa and JPM plants remove particulate matter.

Dairyland Power Cooperative is adding more state-of-the-art air emissions control equipment at its Genoa #3 (G-3) and John P. Madgett (JPM) coal-fired power plants. G-3 is located in Genoa, Wis. JPM is located in Alma, Wis.

After completion of these projects, Dairyland will have invested approximately $325 million for air emissions control work at both facilities since 2007. The result of the new air emission control equipment will be a significant reduction in emissions of sulfur dioxide, nitrogen oxides, mercury and particulate matter.

Completed projects

Installation of “baghouses” to remove particulate matter from the exhaust gas stream at both the G-3 and JPM power plants has resulted in major reductions in particulate matter. The baghouses are in addition to the existing electrostatic precipitators, which capture particulate matter that is recycled as an additive to concrete.

A Semi-dry Flue Gas Desulfurization system or “scrubber” is in operation at the G-3 plant. This technology is a sorbent injection process, which sprays a limestone slurry into chambers between the boiler and fabric filter baghouse, to remove sulfur dioxide and other acid gases. The “scrubber” process also cools the flue gas, thereby drying the reagent so it can be collected in the baghouse.

Projects planned and underway

Construction will begin in 2014 for a Selective Non-Catalytic Reduction “SNCR” system and an Activated Carbon Injection “ACI” system at G-3. These technologies will reduce emissions of nitrogen oxides and mercury. The SNCR system injects liquid urea into the upper levels of the boiler. The urea converts to ammonia and reacts with nitrogen oxide, converting it to nitrogen gas and water vapor. The ACI system injects activated carbon into the flue gas stream. The activated carbon absorbs mercury present in the flue gas and is captured by the baghouse.

At the JPM power plant, construction of a Dry Sorbent Injection “DSI” system and an Activated Carbon Injection “ACI” system will be completed in mid 2014. The DSI system injects sodium bicarbonate “SBC” into the flue gas stream. The SBC reacts with sulfur dioxide and other acid gases, which are then captured by the baghouse. Between them, the DSI and ACI systems reduce sulfur dioxide and mercury emissions.

Selective Catalytic Reduction

JPM Selective Catalytic Reduction Project

Construction of a Selective Catalytic Reduction “SCR” system at JPM will also start in 2014. This system uses an aqueous ammonia reagent and catalyst to react with the nitrogen oxides (NOx) in the flue gas. The ammonia reacts with nitrogen oxide, converting it to nitrogen gas and water vapor, thereby reducing the emissions level of NOx.

The major feature of the SCR construction work at JPM will be the two large catalyst reaction ducts that will be mounted near the electrostatic precipitators. The ductwork and supporting structure will physically change the appearance of the JPM power plant and will extend above the existing plant buildings. In order to erect the steel for this structure, a large construction crane with a boom extending 300 ft., will be set up to maneuver the steel assemblies into place.

Construction work on this particular project is expected to be complete in mid 2016.

Click here for background information on the JPM power plant.

Click here for background information on the G-3 power plant.