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·
Mercury Removal Market to Exceed $1 Billion/yr By 2015
·
China Air Filter and Fabric Filter Markets Are Competing
·
Revenue Potential for Outsourcing of Fossil-Fired Power Plant Processes Is More
than $20 Billion/yr
·
Renewable Energy Briefs
·
Utility E-Alert Headlines –August 29, 2014
·
“Power Plant Pumps” is the “Hot Topic” on September 11, 2014
·
McIlvaine Hot Topic Hour Registration
Mercury Removal Market to Exceed $1 Billion/yr By 2015
Next year U.S. utilities, industrial boilers and cement plants will be required
to limit mercury emissions from stack exhausts. This set of laws alone
will immediately double the market for mercury removal consumables and hardware.
When this new opportunity is combined with the markets in waste
incineration, mining and oil and gas, the total will exceed $1 billion/yr.
This is the conclusion reached in the
McIlvaine Mercury Air Reduction Market. (www.mcilvainecompany.com)
The largest established market is waste incineration.
Waste-to-energy plants around the world have invested in mercury reduction
systems. Early European systems installed in the 1980s utilized moving
carbon bed reactors following wet scrubbers. France was the first adopter
of dedicated fabric filters with powdered activated carbon injection. Various
adaptations of this technology have been embraced in Asia, the Americas and
elsewhere. As a result, waste incineration plummeted from being the
leading source of mercury pollution to where it was far below power plants,
cement plants and other sources.
The new sets of regulations address a much larger market. The U.S. power
plant market will be over $0.5 billion/yr. Only 10 percent of the
coal-fired power plants are in the U.S. So, the ultimate market worldwide
is very substantial. China has passed rules for power plants which allow
mercury emissions at ten times those of the new U.S. regulations. However,
China plans to tighten the standards to the U.S. levels by 2020.
There is a need to remove mercury in natural gas to a few ppb. The reason
is that mercury attacks materials in heat exchangers and other process
equipment. With all the unconventional new sources of natural gas, the
mercury reduction market in this sector is increasing substantially. The
largest single increase will be in China where there are plans for 40 projects
to convert 1.5 billion tons of coal per year to gas, chemicals and gasoline.
Most of the plants will use indirect gasification and will need to reduce
mercury from the product gases. Since the U.S. burns less than 1 billion
tons of coal per year to generate electricity, the Chinese coal to fuels market
alone will be 1.5 times larger. Since China burns 3 billion tons of coal
per year for power generation, the total market will be 4.5 times larger.
There is substantial investment in mercury control technologies. Many
advances are being achieved in:
·
Activated carbon efficiency vs. cost
·
Non-carbon sorbents such as silicates and kaolin
·
Halogen chemicals to make mercury soluble
·
Chemicals to prevent re-emission from scrubbers
·
Treatment of fuel prior to shipment to the power generator
For more information on Mercury Air Reduction Market, click on: http://home.mcilvainecompany.com/index.php/markets/2-uncategorised/85-n056
China Air Filter and Fabric Filter Markets Are Competing
Suppliers of filter fibers and filter media in China will supply more products
for dust collectors and fewer products for indoor air and face masks if
government plans are fully implemented. Air pollution in large cities such
as Beijing and Shanghai is a major health threat. Throughout 2013 the Air
Quality Index in Beijing was typically in the “severe pollution” category.
In Shanghai in December 13, the Index rose to the level deemed “poisonous.”
This low ambient air quality is spurring sales of indoor air filters and face
masks.
The government plan is to correct this problem in part by enforcing tough
particulate emission standards on cement, power and other emitters.
According to the McIlvaine
World Fabric Filter and Element Market
report the market for dust collector bags in China in 2014 will be less than $1
billion. This could increase to well over $2 billion in 2020.
The present market for indoor air filters is $800 million according to the
McIlvaine
Air Filtration and Purification World Market.
When you add the amount the Chinese spend on face masks (extracted from other
McIlvaine reports), the present combined revenues are similar to those for dust
collector bags. The plan would result in only modest growth in the air
filter market, a flat or declining facemask market and a booming market for dust
collector fabrics.
The Chinese government is supporting a campaign to boost filter media
manufacturing within China. Filtration fiber production is projected to reach
1.4 million tons by 2020. The market could be even larger if the power
plants convert from precipitators to fabric filters. They would require 300,000
tons of fiber initially and 100,000 tons per year.
High temperature fibers such as PPS will be needed for coal-fired power plant
filters. Presently, PPS resin production is only 30,000 tons and fiber
production is 20,000 metric tons, so major expansion of high temperature fiber
production will be required.
The major fiber used in dust collectors in China is polyester. Presently,
600,000 tons is used for all filtration applications. The need for better
filtration efficiency for low temperature applications will lead to an expansion
of this market as well.
For more information on
World Fabric Filter and Element Market,
click on:
http://home.mcilvainecompany.com/index.php/markets/2-uncategorised/110-n021
For more information on Air Filtration and Purification World Market, click on http://home.mcilvainecompany.com/index.php/markets/2-uncategorised/108-n022
Revenue Potential for Outsourcing of Fossil-Fired Power Plant Processes Is More
than
$20 Billion/yr
Fossil-fired power plants around the world expend more than $400 billion
to operate their facilities. More extensive outsourcing could improve
operation of these facilities with at least a 10 percent savings. This is
a multibillion dollar opportunity concludes the McIlvaine company in the latest
additions to
Fossil and Nuclear Power Generation: World Analysis and Forecast. (www.mcilvainecompany.com)
There are many ways to reduce costs. They include:
·
Reduce fuel costs and increase efficiency
·
Reduce other consumables expenditures
·
Decrease labor
·
Decrease other maintenance and operating costs
·
Improve fleet operations
·
Generate additional revenue streams
The operation of power plants is becoming increasingly complex.
Fortunately, there are new tools to deal with the complexity. These tools
can be most efficiently employed by specialists. Remotely located
optimization systems can operate plants more efficiently than onsite personnel.
Maintenance tasks can be scheduled based on need rather than routine. This
is in part due to smart valves and pumps which communicate their health
automatically.
Fleets which include renewable generation (wind and solar) increase the
complexity of management due to energy source fluctuations. The complexity
in environmental laws which require a fine balance between opposing needs make
outside expertise particularly important. SO2 can be decreased,
but CO2 is increased. NOx can be decreased, but CO
is increased. The operator must continually strike the optimum balance.
Day-to-day changes in the prices of pollution allowances, fuel and other factors
make it desirable to outsource decisions to a supplier who can invest in the
software and infrastructure to deal with these challenges.
There is a big potential to reduce the expenditure for consumables. For
example, all the filter purchases can be outsourced. Continuous monitoring
tools such as broken bag detectors and continuous emissions monitors capable of
measuring individual metals, acid gases and other pollutants allow a third party
to remotely make filter inspection and replacement decisions. A medium
size power plant can have more than 15,000 filters in operation. Savings
in purchasing and inventory can be significant with the large volumes involved.
The ownership and operation of pollution control systems can be outsourced.
NIPSCO has outsourced the ownership and operation of a flue gas desulfurization
system at the Bailly station since the 1990s. Air Products and Mitsubishi
formed a partnership to provide the operation and maintenance. The program was
quite successful in meeting emissions goals and minimizing consumption of
limestone and energy.
Another big potential is for outsourcing of a “continuing education” program for
plant personnel. There are both general as well as specific needs. Many general
training options are available, but outsourcing provides a unique option for
supplying the specific day-to-day needs to make the important decisions.
For more information on
Fossil and Nuclear Power Generation: World Analysis and Forecast,
click on:
http://home.mcilvainecompany.com/index.php/markets/2-uncategorised/113-n043.
Renewable Energy Briefs
Foundation Design Challenges for World’s Largest Offshore Windmills
Off the
shores of South Korea, South Dakota School of Mines & Technology professor
Sangchul Bang is making history. Designing suction pile foundations for a
2,500-megawatt (MW) wind farm, his nearly $200,000 contract with Korea Electric
Power Corporation Research Institute (KEPRI) will result in foundations for 500
windmills ranging from 3 MW to 7 MW each the largest ever constructed.
The
world’s current record holder stands at 5.5 MW, a prototype with the potential
to power 1,100 households each year.
Housed
underneath the towers, embedded in the seafloor, suction pile foundations are
large-diameter and hollow, a structure Bang likens to an upside-down cup.
Installed with a pump, they suck water out from the top and support the windmill
above against external loads such as self-weight, wind, ocean currents,
earthquakes, collisions and the like.
The
current project presents a unique challenge as each type of windmill 3 MW, 5 MW,
5.5 MW and 7 MW will have a different configuration with varying lengths and
number of blades as well as variant soil conditions, such as clay layers or
sand, from one site to another. Thus, the foundation of each windmill must be
designed individually.
United
Wind Leasing Model Seen as Promising Development for Distributed Wind Power
The
U.S. Department of Energy (DOE) recently released their 2013 Distributed Wind
Market Report summarizing 2013 industry highlights, including the advent of
third-party financing, which is expected to positively affect the market in
subsequent years. The purpose of the report is to help guide future investments
and decisions by industry players, including utilities, government agencies, and
other interested parties.
Distributed wind, which accounted for 80 percent of last year’s U.S. wind
turbine installations, is the installation of turbines to offset all or a
portion of local energy consumption. Differentiated from power generated at
large wind farms, distributed wind projects’ power is used at homes, farms, and
businesses, allowing these property owners to benefit from reduced electric
bills.
While
2013 had 30.4 megawatts (MW) of distributed wind capacity added, the report
indicates that installed distributed wind capacity will be higher in 2014, in
part due to new leasing options introduced to the market.
Fluor
Completes 170 MW Centinela Solar Energy Facility in Southern California
Fluor
Corporation has completed the engineering, procurement, construction and
commissioning for both phases of LS Power’s new Centinela Solar Energy Facility,
one of the largest of its kind in the United States. Located near El Centro, CA,
the 170-megawatt photovoltaic solar project will provide clean, renewable energy
in the southwestern U.S.
The
Centinela facility is the second major solar plant that Fluor has designed and
built for LS Power. In November 2013, Fluor announced the completion of the
125-megawatt Arlington Valley Solar Energy II facility in Maricopa County, AZ.
LS
Power is an independent power company that develops, owns, operates and invests
in power generation and electric transmission infrastructure throughout the
United States.
Viaspace Giant King Grass Reports Progress on Nicaraguan 12 MW Power Plant
Viaspace Inc. has issued an update on the Giant King Grass power plant and
animal feed projects in Nicaragua.
Viaspace CEO Dr. Carl Kukkonen traveled to Nicaragua in August to participate in
the formal power plant feasibility study being conducted by Pelican SA of
Managua. The feasibility study team met at the plantation on the shores of Lake
Nicaragua to assess the agricultural aspects of the project and to inspect
potential sites for the power plant and survey the route for the transmission
line to connect to the national grid.
The
agricultural feasibility study team included experts from Nicaragua, Costa Rica,
Europe and the United States. The team reviewed plans for planting, growing,
harvesting, transporting and processing 284,000 tons of fresh Giant King Grass
every year for the 12 MW biomass power plant. The team heard from the local
Energia Reino Verde team that has been growing Giant King Grass in Nicaragua
since 2012. Energia Reino Verde (English translation "Green Kingdom Energy") is
the special purpose company that will own and operate the 12 MW biomass power
plant and 2,100 acre Giant King Grass (GKG) plantation in Nicaragua.
NEC
Energy Solutions to Install Energy Storage System in California
NEC
Energy Solutions, a leading energy storage system manufacturer, has been awarded
a contract to supply a 2.5MW, 3.9MWh GSS™ to one of the largest electric
utilities in the United States. As a key part of a distributed energy
storage integration program, the GSS, or Grid Storage Solution, will be used to
support analysis of the value streams that energy storage can provide to
utilities, ratepayers, and other involved parties.
For
this project, NEC Energy Solutions will supply a building-based LD (Long
Duration) type GSS, which will be located in a distribution circuit in
California. To support the LD GSS, NEC Energy Solutions will provide a
purpose-built facility to house the storage solution. The custom building
will be designed by NEC Energy Solutions to maximize the value of the battery
configuration by not only hosting the LD GSS, but also integrating the solution
with client power delivery systems.
The LD
GSS, which utilizes lithium ion cell technology, is a flexible modular energy
storage platform which can be packaged in standardized 20-foot, 40-foot, and
53-foot long containers, or installed in either pre-existing or custom-built
buildings to fit the available space.
For more information on Renewable Energy Projects and Update
please visithttp://www.mcilvainecompany.com/brochures/Renewable_Energy_Projects_Brochure/renewable_energy_projects_brochure.htm
Headlines for Utility E-Alert – August 29, 2014
#1189 – August 29, 2014
Table of Contents
COAL – US
· Minnesota Power to Operate Baghouse at Boswell 4 by 2016
· EPA wants comments on Four Corners proposed Permit for upgrade on Two Coal-fired Units
·
Mississippi Supreme
Court sides with Mississippi Power on Emissions Control Regulations
·
Consumers Energy
nearing completion of $250 Million Upgrade Project at Karn/Weadock
· Duke Energy retiring Coal Operations at W.C. Beckjord Station in Ohio
GAS/OIL - US
· Lackawanna Energy to build 1,300 MW Power Plant in Pennsylvania
·
Calpine to acquire Fore River 809 MW Gas-fired
Power Plant in Massachusetts from Exelon
GAS/OIL - WORLD
·
Reliance Power opts
out of Gas-fired Power Plant in Dadri Uttar Pradesh, India
· APR Energy signs Contract for Peaking Power Plant in Australia
·
L&T to construct
225 MW Sikalbaha Gas-fired Power Plant in Bangladesh
· Santerre Limited to develop a 200 MW Combined Cycle power plant in Ghana
· Foster Wheeler HRSG for Kimberly Clark Facility in Mexico
CO2
BUSINESS
· Scrubber Market veering from Hardware to Consumables
HOT TOPIC HOUR
For more information on the Utility Tracking System, click on:
http://home.mcilvainecompany.com/index.php/databases/2-uncategorised/89-42ei
“Power Plant Pumps”
is the “Hot Topic” on September 11, 2014
This webinar on September 11 will be both organizational and informative.
It is all part of a whole knowledge system for gas turbine combined cycle plant
operators --
Gas Turbine and Combined Cycle Decisions
. The free website and periodic webinars empower the operators to
buy the best products rather than the most familiar or least expensive.
The webinar on the 11th will try to answer the question: What are
the most important and difficult decisions you will have to make regarding
pumps?
Here are some of the questions which will be addressed:
Where do you use variable speed drives? (William Livoti of WEG will lead this
segment of the discussion.)
What type of boiler feedwater pump is best?
With fast start HRSGS and constant cycling, what pump innovations will counter
some of the negative consequences of this operating mode?
What pump issues facing GTCC operators which are unique to this type of power
generation?
What are the pump needs if zero liquid discharge technology is mandated?
What other questions are GTCC operators asking?
Here is a list of pumps used in gas turbine combined cycle plants:
The power plants participating in the webinar will have free access to
Gas Turbine and Combined Cycle Decisions
. In order to make the webinar most valuable to these operators, it is
recommended that they review the following information on the site.
VFDs can make a big difference in optimizing pump energy consumption in cooling
tower makeup
William Livoti writing in “Empowering Pumps“discusses some of the
potential regulations which will force recycling of cooling water. He says that
power plants need to assess their pump requirements and consider variable speed
drives to reduce energy consumption. He cites the advantages when handling off
peak loads. A specific example is given for the VFD saving with cooling water
makeup pumps.
HERE ARE SOME OF THE ARTICLES REPORTED IN CCJ
Hydro, Inc. is largest independent pump rebuilder
As the largest independent pump rebuilder, Hydro works hand-in-hand with pump
users to optimize the performance and reliability of their pumping systems.
Hydro’s mission was developed in 1969 when Hydro realized that as an independent
pump rebuilding company, Hydro had a unique capability of analyzing and
understanding various designs as well as their successes or failures in specific
applications and operating environments.
City of Tallahassee, FL Unit 2A, A B Hopkins Generating Station Size 300 MW
Commercial operating date: June 2008 EPC contractor: BE&K, Inc. Owner’s
engineer: Sargent & Lundy Type of plant: Combined Cycle Gas Turbine
Manufacturer: GE Energy Wet Cooling Tower: Hamon-Custodis (existing) Boiler-feed
pumps: Flowserve Corp Boiler-feed-pump drives: Voith Turbo, Inc. Condensate
pumps: Existing Condensate booster pumps: ITT Goulds Pumps Booster-pump drives:
Voith Turbo, Inc. Circulating-water pumps: Johnson Pump, an SPX brand
(Existing).
Pump relocation is one best practices at the CTOTF® spring meeting
Circulating pumps for the evap cooling systems serving 7EAs located in the
western desert were installed on the second level inside the inlet air house.
Failure of a pump required its replacement under demanding conditions, high off
the ground, and likely when the GT was in operation. Certainly not ideal.
Plant personnel relocated the two pumps (one redundant) for each unit at ground
level. There have been no pump failures or system degradation issues since the
modification was made.
Tenaska Lindsay Hill Generating Station ammonia pump problem
The facility’s anhydrous-ammonia forwarding pumps did not allow for double-valve
isolation during maintenance. These pumps are only required for use on very cold
days. This requires additional maintenance and laying them up for periods of
non-use. The system had single-valve isolation from the ammonia storage tank to
the suction of the pumps, a potential safety risk for the O&M team.Solution.
Plant management decided to install double-block-and-bleed capabilities to the
liquid suction line from the storage tank and liquid return line to the storage
tank.
OTHER ARTICLES APPEARING IN THE MCILVAINE GAS TURBINE AND COMBINED CYCLE
DECISIONS UNDER THE KEYWORD “PUMPS”
Bottom of Form
MHI and Shenyang Pump Co., Ltd. (SPC) have agreed to establish a joint venture
company (JV) in Shenyang, Liaoning Province, China to conduct sales and
engineering relating to pumps. The agreement was signed on March 23 in Shenyang.
With establishment of the JV, MHI aims to make a full-scale entrance into the
Chinese pump market, where demand for pumps of all kinds is expected to increase
vigorously. The focus is on pumps for thermal power plants. Creation of the new
JV will enable MHI and SPC to build further experience in collaborative
activities, as a prelude to possible establishment in the future of a
manufacturing JV to serve as a local production base for a variety of pump
products.
Sulzer high pressure barrel casing pump designed for boiler feedwater
The HPT is a pump specifically designed for boiler feed applications in thermal
power stations. The pumps are optimized to provide high-efficiency operation
over an extended period of time, thus reducing operating and maintenance costs.
MHI supplies ring section boiler feedwater pumps for combined cycle operation
MHI supplies a variety of pumps for combined cycle and coal-fired power plants.
Several boiler feedwater designs are available depending on pressures and other
parameters. The ring section type is used in combined cycle.
Flowserve Boiler Feedwater pumps have beneficial features
The boiler feedwater pumps must handle high pressures and fairly high flow rates
and for these services between bearing multistage pumps are commonly used. For
very high pressure, double case pumps are sometimes required; Flowserve models
DMX and WXH are commonly used. These between bearings, multistage pumps offer
the following features and benefits: Choice of axially or radically split case
-- Ease of maintenance. Choice of volute or diffuser case construction
--Fluid dynamics best suited for application. Double-suction first-stage
impeller (option) ------------Minimizes NPSHR Flanged balance drum or
hydraulically balanced rotating unit--------Balances hydraulic thrust and
reduces vibration Finned bearing housing--- Maximizes heat dissipation.
The standardized Sulzer Pumps MD raqnge meets GTCC boiler feed requirements
Although most once-through HRSGS are subcritical, their BFPs have to provide
very high pressure. In order to increase pressure, BFPs have more stages
and shafts with higher torque capacity than conventional pumps. The Sulzer MD
range meets these requirements.
Mitsubhishi and BHEL team up to provide power plant pumps in India
Bharat Heavy Electricals Ltd, the country’s biggest power equipment supplier,
signed an agreement with Mitsubishi Heavy Industries Ltd in 2007 under which the
Japanese firm will license technologies relating to pumps used in thermal power
plants.
The SPX's diffuser type pump CUP-FT/FK (2 Pole), ClydeUnion Pumps, offer flows
up to 4,840 m3/h, delivering up to 8,200 m, on maximum temperatures of 350°C,
with operating speed up to 3,600 rpm.
High-pressure diffuser barrel multistage DDHM pumps (API610 / ISO13709 type BB5)
are designed for ultra-reliability and efficiency in the most demanding onshore
and offshore water-injection applications. They are also well suited for boiler
feedwater, pipeline, amine, energy recovery and CO2 injection.
During the selection process, we can tailor the complete system to specific
customer objectives in terms of CAPEX, OPEX and operability. This service
includes matching of the main and booster pumps as a crucial step in optimizing
performance.
Boiler feedwater pump for Dubai Fertilizer from SPX Clyde Union
This quote for a $300K BFP is not for GTCC but does provide very useful and
detailed information of what is included and terms and conditions. The unique
appearance of a document such as this on the internet adds to its value.
SPX offers pumps and many other components for GTCC plants
This brochure covers the complete range of SPX products for the power industry.
Good diagrams on GTCC show the boiler feed pumps and other offerings.
Since SPX also offers complete cooling tower systems they can offer pumps as
part of packages or separately.
Grundfos has pumps for steam boilers and district heating
Grundfos supplies the high pressure multi stage pumps for steam boilers. It is a
leader in pumps for district heating. Gas turbine combined cycle plants are
often replacing coal plants in district heating systems. At the same time, the
distribution systems are being upgraded with new pumps.
The webinar is free to power plants.
Click here to view schedule and register
McIlvaine Hot Topic Hour Registration
On Thursday at 10 a.m. Central time, McIlvaine hosts
a 90 minute web meeting on important energy and pollution control subjects. Power
webinars are free for subscribers to either Power Plant Air Quality
Decisions or Utility Tracking System. The cost is
$300.00 for
non-subscribers.
See below for information on upcoming Hot Topic Hours. We welcome your input
relative to suggested additions.
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Click here for the
Subscriber and Power Plant
Owner/Operator Registration Form
Click here for the
Non-Subscribers Registration Form
Click here for the Free
Hot Topic Hour Registration Form
----------
You can register for our free McIlvaine Newsletters at:
http://home.mcilvainecompany.com/index.php?option=com_rsform&formId=5
Bob McIlvaine
President
847 784 0012 ext 112
rmcilvaine@mcilvainecompany.com
