Sargent & Lundy

Coal-Fired Dry Fork Station Unit 1

Mine-mouth greenfield station deploys advanced environmental control technology

Gillette, Wyoming
New Coal Plant/ 422 MW /Powder River Basin pulverized coal
Client: Basin Electric Power Cooperative (BEPC)

The new mine-mouth power plant uses low-sulfur Powder River Basin coal and had to meet stringent environmental standards.  The plant is a zero-discharge (liquid) facility and all air emissions were minimized through state-of-the-art air quality technologies and controls:

  • Selective catalytic reduction (SCR) for NOX
  • Circulating dry scrubber for SO2
  • Pulse jet fabric filter for particulate control
  • Activated carbon injection (ACI) system for mercury control

Sargent & Lundy was selected by BEPC to provide complete detailed design, procurement, and construction management services for the project. The plant was designed to add reliable and economical generating capacity to help meet the needs of BEPC’s more than 130 cooperative system members and Wyoming Municipal Power Agency. The project was performed with active input and involvement of BEPC during design and construction as a collaboration to achieve the shared goal of meeting cost and schedule requirements.

Project Scope:

  • Development of plant performance criteria, heat balances, and water balances
  • Procurement and contract management of equipment for the power cycle, balance-of-plant, electrical systems, structural steel, switchyard equipment, secondary fuel systems, and plant auxiliary systems
  • Contracting for furnish and erection of the boiler, flue gas desulfurization system, coal handling, air-cooled condenser, activated carbon injection, fire protection/detection/alarm, chimney, and elevators
  • Contracting for installation of site work, substructures and foundations, superstructures, switchyard, electrical systems, mechanical equipment, piping, and other services
  • Quality inspection, surveillance, and expediting
  • Construction management
  • Material and equipment control

Project Awards

In 2012, Dry Fork Station was named the 2012 Best Industrial Project in the annual Engineering News‑Record (ENR) Mountain States competition.  Judging for ENR‘s Best Project honors is held in nine regions of the United States based on the project’s location. Owner Basin Electric Power Cooperative and project engineer Sargent & Lundy were recognized for the project’s accomplishments.

Read article in Engineering News-Record

In the 2008 Bentley Awards of Excellence Competition the project won 1st place honors in “Innovation in Power Generation Project Design.” The advanced-generation coal-fired station earned the award for effectively using 3‑D design model exceeding 2000 files to facilitate design optimization and constructibility and to reduce total project cost and ongoing O&M costs.

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James Malone

Director of Business Development




Jim brings 36 years of knowledge to the Power Generation Industry including comprehensive consulting, design engineering, product understanding and analysis for projects worldwide.