Expera Specialty Solutions ~ IBMACT Project

Kaukauna, Wisconsin

Project Description

The Expera IBMACT project was required in order to meet the Industrial Boiler MACT air emissions standard compliance. Boldt’s scope of work includes the addition of an air filtration system in order to remove chlorine from the exhaust of coal-fired boilers. This is done by bonding hydrated lime with the chlorine particles in the exhaust. Ash is formed and collected in a baghouse where it will gather over time. Once accumulated, pressurized air cleans the bag and the ash is sent to a silo for storage. From there it is loaded into trucks and disposed of in a landfill.

The scope of the project includes the installation of the pulse jet fabric filter baghouse, Dry Sorbent Injection System, 1250 HP ID fan and ductwork to route the boiler flue gases from the three existing power boilers to the Sorbent Injection system through the PJFF and back to the existing stack.

The crane that the IBMACT job received was smaller than originally planned. This resulted in significant changes to the ductwork sizing to allow for the crane to pick and set the ductwork. Boldt put together a very detailed lift plan for each piece of ductwork. The DSI silo and the truss bridge required a large effort from the project team to determine how the cranes would be able to pick the equipment in such a small space.

To help the tradesmen visualize the final ductwork and structural steel, Boldt loaded A360 software on iPads and iPhones to allow for them to see a 3D rendering of the final installation. This helped to understand how the steel and ductwork would fit into the plant.

Learn more about our work in the industrial market or our consulting technical/capabilties

Architect/Engineer

PEC, Poyry, The Boldt Company

Boldt's Role

Construction Manager

Key Points

  • The crane that the IBMACT job received was smaller than originally planned.  This resulted in significant changes to the ductwork sizing to allow for the crane to pick and set the ductwork.