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Minnesota Power (MP), based in Duluth, Minnesota provides electric services to around 144,000 retail customers, and about a dozen large industrial enterprises in northeast Minnesota. The majority of the power at Minnesota Power is generated from low-sulfur, low-mercury coal from the Powder River Basin. Faced with ever-more-stringent emission regulations at the state and federal level, the company initiated a $240 million project in 2006 to reduce emissions from the 350 megawatt Boswell Energy Center Unit 3, company’s second largest generation unit.
In this video: Al Rudeck, Vice President of Generation at Minnesota Power gives overview of Minnesota Power
and explains the project with Hitachi Power Systems America. (0:47) (interviewed in February, 2011)
Hitachi Power Systems America (HPSA) provided a comprehensive technology solution that helped Minnesota Power meet their lower emission targets as the part of aggressively scheduled three-year project. The retrofit package from Hitachi Power Systems America included Selective Catalytic Reduction system and Wet Flue Gas Desulfurization system.
In this video: David Paz, Regional Sales Manager at Hitachi Power Systems America discusses the relationship
with Minnesota Power and the process in working with Minnesota Power on their Boswell Unit 3.
Hitachi Power Systems America successfully constructed and tested the Minnesota Power’s retrofit project, which resulted in a 99 percent reduction in sulfur dioxide (SO2) emissions and a 92 percent reduction in nitrogen oxide (NOx) emissions.
*Source: Minnesota Power
Go through the next sections of Hitachi case studies to get detailed information on how Hitachi Power Systems America helped Minnesota Power (MP) to meet the emission regulations for their Boswell Energy Center Unit 3.
Minnesota Power (MP)
Products & Services
Selective Catalytic Reduction (SCR) system, Flue Gas Desulfurization (FGD) system
May, 2011, prior to Hitachi Power Systems America’s business transfer to Mitsubishi Hitachi Power Systems
Hitachi Power Systems America, Ltd.
Minnesota Power (MP) commenced a proactive emissions reduction project at the Boswell Energy Center Unit 3, with aim to reduce emissions of sulfur dioxide, nitrogen oxides, particulate matter, and mercury, in advance of the implementation of new environmental emission regulations. Minnesota Power needed the support of technology suppliers, engineers, and construction contractors, and looked for a technology supplier to help complete their mission.
In this video: Al Rudeck discusses the complexity and proactive decision to embark on
Boswell Unit 3 emissions reduction project, including decision of choosing HPSA for project. (1:15)
For the Boswell 3 plant, Minnesota Power commenced a proactive project to reduce sulfur dioxide emissions by 99 percent, nitrogen oxide emissions by 92 percent, mercury emissions by 95 percent, and particulate matter by 95 percent.
They determined that their project scope would include the following Air Quality Control System equipment:
MP sought support of several technology suppliers, who could achieve the project emission goals. Through a competitive solicitation process, Hitachi Power Systems America offered a solution, which included the SCR system, WFGD system, and interconnecting ductwork as a comprehensive system, along with a complete set of guarantees for their entire supply.
The state-of-the art technology of Hitachi Power Systems America stood out from the competition. Being at the forefront of SCR technology innovation and a world leader of SCR systems and NOx catalyst, HPSA was uniquely positioned in the power generation industry as a provider of complete coal-fired SCR systems, featuring their proprietary plate type catalyst and patented SCR reactor hood.
In this video: Tom Coughlin, Project Manager, Minnesota Power, shares goals for the project,
importance of selecting the right partner to achieve success, and how this was achieved.
(0:41) (interviewed in February, 2011)
Minnesota Power established an aggressive three-year schedule for the execution of complete emission reduction project, and the commitment done by Hitachi Power Systems America to meet this schedule strengthened their selection for the project team.
Hitachi Power Systems America provided a comprehensive package of equipment to Minnesota Power that included a Selective Catalytic Reduction (SCR) system, a Flue Gas Desulfurization (FGD) system, and an interconnecting ductwork.
Both HPSA systems incorporated vital components to resolve MP’s challenge, and included following:
In this video: David Paz discussed Hitachi Power Systems America’s technology expertise
and proprietary Catalyst design. (1:09)
To meet the aggressive project timeline, a collaborative effort between Hitachi Power Systems America, Minnesota Power, and their engineering & construction contractors was crucial.
In this video: Don Miller, Site Construction Manager, Hitachi Power Systems America,
shares challenges and collaboration between Hitachi Power Systems America and Minnesota Power
during the 3-year project. (0:49) (interviewed in February, 2011)
Hitachi Power Systems America brought together a highly experienced project team that included project director, construction manager, procurement specialists, engineers, and others. Together, they executed the design and procurement effort in a timely manner to support the project construction and start-up schedule. Constant interaction between HPSA and the MP team in an open and cooperative atmosphere ensured success of this complex retrofit project.
After the construction completed in November 2009, Boswell Unit 3 resumed operations and carried out performance tests by February 2010.
In this video: Rick Fannin, Operations Superintendent, Minnesota Power,
discusses highlights of project and performance testing following completion of the project and success
achieved through various upgrades made to Boswell Unit 3. (1:01), (interviewed in February, 2011)
Minnesota Power surpassed all of its emissions goals with the following results:
*Source: Minnesota Power
In this video: Al Rudeck shares results on emission reduction and benefits to the community
after successful completion of the project. (0:43)
The operation of the equipment supplied by Hitachi Power Systems America met all expectations, while the follow-up inspections confirmed the equipment to be in proper working condition.
As a total solution provider, HPSA has continued to support and serve Minnesota Power through its Aftermarket Group for Boswell Unit 3 and its future AQCS (Air Quality Control System) needs.
Hitachi Power Systems America, Ltd. (HPSA) is a wholly owned subsidiary of Hitachi America, Ltd. HPSA provides engineering, procurement, and project management services associated with boiler, turbine, and Air Quality Control System (AQCS) requirements for new plants and retrofit applications.
As a part of Hitachi’s evolving strategy, Hitachi Power Systems America focuses on the growth in regional markets to improve existing facilities and Greenfield installations in the North American Power Market. Hitachi recognizes US as one of the largest consumers of electricity in the world, and commits to support the growth of the industry with its outstanding portfolio of products and services. The stable price and ample supply of coal is creating brisk demand for new plant construction. Stringent environmental standards are stimulating demand for the retrofit type of products that form a part of Hitachi's core competency.
Hitachi Power Systems America also houses the Company’s Global Center of Excellence for the Power Emissions Market, including Wet Flue Gas Desulphurization, Selective Catalytic Regeneration, Catalyst Sales, and Total Air Quality Control Systems Solutions.
HPSA is based in Basking Ridge, NJ, and has an experienced staff that possesses a broad-based background in power generation and pollution control practices. Henry Bartoli heads the company as President and CEO. Earlier, he had served as Executive Vice President of the environmental businesses of Hitachi America, Ltd. - Power and Industrial Division.
The Minnesota Power (MP), based in Duluth, provides electric service to around 144,000 retail customers and about a dozen large industrial enterprises in northeast Minnesota. Its largest asset is the Boswell Entergy Center, a coal-fired plant in Cohasset, Minnesota, which has a total power output of over 1,025 megawatts (MW) from four units.