Case Study

Coal Additive System


Coal Power Plant

Emission Reduction, Industrial, Power Plant

The Challenge:

The client had developed a process to reduce emissions at a coal power plant in Arizona, but needed assistance with designing equipment to apply the materials. In addition to designing the bulk material handling system and vessels required for the application, the client also needed to structurally retrofit an existing building to accommodate the new equipment, without negatively impacting the plant’s operations. There was also a firm deadline to meet government stipulations, which severely limited the design, engineering and construction schedules to meet the deadline.

The Solution:

Due to the schedule restraints of the project, and extensive lead times, prefabricated vessels were not a feasible option. By partnering with a fabrication company early in the project, Halker was able to design custom vessels and valves to tie into a bag house. The custom vessel fabrication also benefited the structural design; the building to house the equipment had minimal space, so unique vessel dimensions and retrofitted structural supports were required to provide accessible equipment for the operations team within the existing building. The material handling system was designed to apply a variable amount of two bulk additives simultaneously on two separate conveyors. Halker’s integrated design team worked closely with the contractor and client to fast-track the schedule and begin construction before all construction documents were finalized.

The Result:

The project was completed on time without interruption to the existing operations of the plant. The bulk material handling system continues to operate efficiently while effectively reducing emissions for the power plant. The additional structure and vessels were tied into the existing infrastructure seamlessly with access for the operations team to regularly operate and maintain the equipment.