Power Plant Uses State-of-the-Art Circulating Fluidized Bed Process

The East Kentucky Power Cooperative (EKPC) services 16 member cooperatives that buy wholesale power.  These member cooperatives serve nearly 500,000 customers in 89 of Kentucky's 120 counties. EKPC's service area was experiencing strong growth.  They realized the power generated at their Spurlock Power Generating Station near Maysville wouldn't be enough to meet the projected future demands.

Stanley Consultants was contracted to provide conceptual, preliminary, and detailed engineering and design; resident engineering; and performance testing for Spurlock Unit 4.  This project consisted of a 268 MW coal-fired circulating fluidized bed boiler generating units.

Four years earlier, Stanley Consultants successfully completed the engineering and design for EKPC, Gilbert Unit 3. Because of this, our engineering team was able to streamline the construction process for unit 4 by negotiating and contracting with the same group of contractors and equipment suppliers who worked on Unit 3.  As a result, conflicts and delays were minimized.

The unit's Circulating Fluidized Bed (CFB) process is state-of-the-art. The CFB technology allows the burning of a wide variety of coals, including low-fusion coals, low cost high sulfur coal, and waste coal, without impacting the environment.  EKPC also plans to burn up to 400 tons, per year, of switchgrass grown and harvested by Kentucky farmers.

As a result, the innovative engineering and emissions control techniques have made Spurlock Unit 4 the cleanest and most environmentally friendly coal-fired generating unit in Kentucky and one of the cleanest in the United States.  The plant's emission levels are well below the EPA's New Source Performance Standards for SO2, NOX, and particulate.