Brandon Shores Generating Station – Maryland
Advanced FGD Wastewater Treatment Using Solids Contact Clarification
Industry: Power Generation
Application: Flue Gas Desulfurization (FGD) Wastewater Treatment
Location: Near Glen Burnie, Maryland
Owner/Operator: Raven Power Holdings, Inc.
Technology: Solids Contact Clarifier with Dual Shaft Lift Drive
Facility Overview
The Brandon Shores Generating Station is a coal-fired electric power facility located near Glen Burnie, Maryland. Operated by Raven Power Holdings, the station includes two Babcock & Wilcox boilers and two General Electric steam turbines, with a combined nominal generating capacity of 1,370 megawatts (MW).
As part of its emissions control strategy, the facility employs Limestone Forced Oxidation (LSFO) flue gas desulfurization to reduce sulfur dioxide (SO₂) emissions from coal combustion. While highly effective for air quality compliance, this process generates a complex, high-strength wastewater stream requiring advanced treatment prior to discharge.
FGD Wastewater Treatment Challenge
FGD wastewater at Brandon Shores originates primarily from the overflow of secondary hydrocyclones in the gypsum dewatering process. This effluent contains elevated concentrations of dissolved and suspended solids, heavy metals, and reaction byproducts that must be removed to meet discharge requirements.
The wastewater treatment process begins with routing the FGD effluent to an equalization tank, providing flow balancing and consistent downstream operation. From there, the system employs a physical-chemical treatment process designed to de-saturate the wastewater, precipitate heavy metals, and reduce total suspended solids through controlled reactions including chemical addition, flocculation, clarification, and dewatering.
ClearStream Engineering Solution
At the core of the Brandon Shores FGD wastewater treatment system is a custom-designed ClearStream Solids Contact Clarifier. Due to the high solids loading and dense sludge characteristics, the clarifier was equipped with a heavy-duty lift mechanism to protect equipment during high-torque events.
ClearStream’s solution features a precision bearing dual-shaft drive with lift, incorporating a shaft-within-a-shaft design that allows the internal impeller to operate independently of the rake arms. This configuration enables the rake structure to be raised out of the sludge blanket without affecting impeller speed or elevation—ensuring continuous mixing and reaction even under variable loading conditions.
The solids contact clarifier also provides internal recycle of settled solids, promoting complete chemical reactions and enhanced flocculation. This internal recirculation produces a denser sludge, improves solids capture efficiency, and supports reliable downstream dewatering.
Results
The advanced FGD wastewater treatment system at Brandon Shores effectively concentrates contaminants into a stable solid cake suitable for landfill disposal. The clarified effluent is discharged to a receiving water body or optionally polished through media filtration to further reduce suspended solids.
By combining robust mechanical design with optimized process engineering, ClearStream delivered a reliable, high-performance solution tailored to the demanding requirements of coal-fired power plant wastewater treatment.
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Brandon Shores Generating Station – Maryland