Water Market Insights No

· “Control and Treatment Technology for FGD Wastewater” is the Hot Topic Hour on Thursday, August 15, 2013

Industrial valve purchases for use in China next year will again grow robustly and surpass $10 billion for the first time. This is the conclusion in Industrial Valves: World Market published by the McIlvaine Company. (www.mcilvainecompany.com)

Industry	Classification	2014
Chemical	Control	233
Chemical	OnOff	768
Electronics	Control	6
Electronics	OnOff	25
Food	Control	46
Food	OnOff	183
Iron & Steel	Control	274
Iron & Steel	OnOff	819
Metals	Control	53
Metals	OnOff	161
Mining	Control	108
Mining	OnOff	363
Oil & Gas	Control	81
Oil & Gas	OnOff	473
Other Electronics	Control	3
Other Electronics	OnOff	13
Other Industries	Control	270
Other Industries	OnOff	759
Pharmaceutical	Control	30
Pharmaceutical	OnOff	84
Power	Control	807
Power	OnOff	2,050
Pulp & Paper	Control	205
Pulp & Paper	OnOff	531
Refining	Control	88
Refining	OnOff	252
Wastewater	Control	174
Wastewater	OnOff	515
Water	Control	232
Water	OnOff	578
Total		10,184

On/Off valves for the power industry will be the biggest segment. Control valves for the power industry will be the third largest segment and nearly equal to On/Off valves for the iron and steel industry.

The Chinese five-year plan, which will add nearly 45,000 MW/yr of new coal-fired power plants supplemented by an ambitious nuclear program, will result in this very large power segment market.

Industrial pump company revenue growth is predicted to be 3.7 percent this year according to the latest forecasts in the continuously updated McIlvaine report, Pumps World Markets. (www.mcilvainecompany.com)

Continent	2012	2013	%
Total	37,012	38,423	3.7
Africa	1,440	1,519	4.9
America	9,965	10,219	2.5
Asia	16,932	17,905	5.9
Europe	8,675	8,780	1.2

Growth in Asia will exceed that of other continents. The lowest growth will be in Europe. However, it should be noted that this is growth in consumption and not production. The pump companies exporting from Europe are expecting higher growth.

In general, the larger pump companies are expecting growth considerably above the mean.

Rankings	Company	2013 Growth %
1	Xylem	11
2	Flowserve	7
3	Grundfos A/S	?
4	Sulzer Ltd.	8
5	Weir Group	5
6	KSB	11

Two of the top six pump companies are expecting double-digit growth. Analysts expect Xylem sales to increase 11 percent this year. Last year sales were flat but were up 18 percent in 2011 and 12 percent in 2010. However, sales were down 13 percent in 2009. Flowserve sales are expected to rise over 7 percent this year following sales increases over 5 percent last year and 12 percent in 2011. Sales were down over 7 percent in 2010.

Sales of devices to measure particles in the air exceed $700 million. This is the conclusion reached by the McIlvaine Company in its continuously updated Air & Water Pollution Monitoring World Markets. (www.mcilvainecompany.com)

The market is very fractured. There are many applications and many types of measurement instruments.

Category	Recent Annual Revenues $ Millions
Opacity monitors-stack	150 (optical measurement)
Mass monitors-stack	100 with $300 million bubble coming
Process gas particulate continuous monitors	40 (measure mass)
Broken bag detectors	30 (determine particulate escaping due to broken filter bags)
Portable method 5 particulate sampler trains	40 (measure weight by collecting sample)
Ambient particulate monitoring stations	50 (measure weight)
Cleanroom particulate network systems	60 (count particles)
Cleanroom portable particle counters	40 (count particles)
Continuous indoor air particulate monitoring	50 (count particles)
Printer and other device particulate monitoring	20 (count particles)
Portable particulate monitors-indoor air	60 (count particles)
Biological viable particulate monitors-portable	50 (capture particles for later culture)
Engine test centers (particulate segment)	70 (particulate segment)
Total	760 (plus mass CEM surge)

The biggest segment is a more sophisticated version of the London smoke chart developed over 900 years ago. The smoke inspector determined whether the stack plume was black, some shade of grey or white. The digital version of the device today is the opacity monitor.

Many applications need more accurate measurement. Mass monitors determine the weight of particulate in the gas stream. New U.S. EPA requirements for power plants, cement plants and industrial boilers are requiring mass measurement. This will create a several hundred million dollar surge in sales.

A very clean exhaust gas stream still contains millions of particles. In fact, clean normal ambient air contains about 500,000 particles per cubic foot. Semiconductor cleanrooms must maintain an air quality of less than one particle per cubic foot. There is no mass measurement method that is of sufficient sensitivity. So particle counting is the only option in cleanrooms and indoor work spaces.

There is a great deal of complexity relative to the definitions. The reported measurements are based on particles of a certain size (generally 0.5 to as low as 0.1 micrometers). This means that particles below 100 nanometers are not measured. Generally these small particles are not sufficient in quantity to be considered. However, with nano technology gaining in popularity, there is the potential for the number of nano particles to be significant.

Another problem is the distinction between discrete and total particulate. New EPA and State rules take into account condensible as well as discrete particles and call the aggregate “total particulate.“ There are challenges in making the measurements and challenges in supplying air pollution control equipment to reduce total particulate to the required levels.

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• Meralco proposes 50-80 MW Power Plant for Philex Mining Corp. in Philippines

• Ultra Mega Power Projects at Cheyyar and Bedabahal in India should be Awarded in Early 2014

• Gemma Power Systems enters into an EPC Agreement with Moxie Patriot LLC for a Gas-fired Power Plant

• U.S. Appeals Court Rejects States’ Challenge of EPA’s Greenhouse Gas Rules

• India Railways could turn to Nuclear Power Plants to Supply Power for Electric Locomotives

• MPSA’S Large Scale SCR System at 800 MW Marsh Landing Simple Cycle Power Plant

• Cogeneration, Fuel Switching, and Upgrades Are All Choices for U.S. Industrial Boiler Operators

• “New Developments in Air Pollution Control Technology - Part 2” – Hot Topic Hour on August 1, 2013

• “Improving Power Plant Efficiency and Power Generation” is the Hot Topic Hour on Thursday, August 8, 2013

“Control and Treatment Technology for FGD Wastewater” will be the Hot Topic on August 15, 2013

On April 19, 2013, EPA proposed revisions to the effluent limitations, guidelines and standards that would strengthen the existing controls on water discharges from steam electric power plants. The rules would require power plants to install pollution control technology and implement waste-treatment procedures in a phased approach between 2017 and 2022. The EPA must finalize the rules by May 22, 2014. The rules apply to all water discharged from steam power plants, but a particular concern is FGD wastewater. The pollutants of concern include mercury, arsenic, selenium, nitrogen and total dissolved solids.

Over the next few years, plant operators will be upgrading their existing SO₂ control systems and installing new systems to meet the new emission limits posed by the utility MATS and CASPR (when finalized). The great majority of existing systems are wet FGDs and it is likely that most new FGDs will be wet because it is difficult for a dry system to meet the new emission limits. These wet FGDs utilize large quantities of water with limestone to remove the SO₂. The proposed water discharge rules as well as increasing regulations limiting the availability and use of water will be of great concern to operators of existing wet FGDs and those power plants considering installation of new FGDs.

It is not an easy task to design an FGD wastewater treatment system that meets or exceeds discharge regulations because the quantity and composition of FGD discharge water varies widely based on the boiler rating, scrubber type, the efficiency of flyash removal, the efficiency of the dewatering system and the composition of the coal, limestone and make-up water used. Most FGDs discharge purge or wastewater that is a slurry of water, dissolved solids and suspended solids laden with heavy metals and salts.

The following speakers will describe the options available to plant operators utilizing or considering wet FGDs to achieve the discharge limits and reduce water usage and discuss their experience with developing, testing, designing and troubleshooting treatment technologies for FGD wastewaters, the advantages and disadvantages of the currently available options including capital and operating costs and the latest state-of-the-art technologies for treating, minimizing or eliminating the wastewater that is generated by wet FGD systems.

Paul Chu, Project Manager at the Electric Power Research Institute, will present the work EPRI has been doing to evaluate wastewater treatment options. EPA recently proposed numeric limits for selenium, mercury, arsenic and nitrate/nitrite for FGD wastewaters. As power plants require cost-effective and reliable treatment options, EPRI has been conducting treatment evaluation studies in the laboratory, pilot and full-scale. EPRI’s work has focused upon physical/chemical precipitation and adsorption based technologies as well as biological reduction approaches.

Norikazu Inaba, Manager of Process Engineering at MHIA /Advatech (A URS & MHIA Company), will discuss “Simple Zero Liquid Discharge System for FGD Wastewater.” MHI has developed low CAPEX/OPEX technology for truly achieving zero liquid discharge (ZLD) from wet FGD to meet the stringent effluent limits. The Wastewater Spray Dryer (WSD) that eliminates a purge stream from the wet FGD process is easy to retrofit and requires no chemicals and significantly less energy than the conventional brine evaporator.

Gordon Maller, Principal Project Manager and Business Development Manager for URS Corporation – Process Technologies Office, will present “Wastewater Treatment and Zero Liquid Discharge Technologies – Overview and New Technology.” New effluent limitation guidelines (ELG) have been proposed by the EPA which will require utilities to provide significantly higher levels of treatment prior to discharge for a number of wastewater streams in contact with coal combustion residuals (CCR) including FGD wastewater. This presentation will provide an overview of the new rules as well as an overview of existing and emerging WWT and ZLD technology to comply with the new rules. New technology and strategies for plants to operate as ZLD at a much lower cost, optimize water usage, and accomplish necessary improvements such as closing waste impoundments will also be discussed.

William A. Shaw, Senior Process Engineer for HPD^® Evaporators and Crystallizers at Veolia Water Solutions & Technologies North America, will present “Zero Liquid Discharge Systems for FGD Wastewater.” In light of proposed EPA Effluent Limit Guidelines, many coal-fired power plants are considering ways to reduce their water discharges. Zero liquid discharge (ZLD) processes are being studied in anticipation of even more restrictions on water discharges in the future. Closing the loop by adopting a ZLD treatment scheme will usually involve consideration of evaporation and crystallization technologies as these have had and will continue to play an important role in the recovery and re-use of water from industrial wastewater streams. However, ZLD systems can be very expensive from both a capital and operational perspective. New approaches to evaporator system design, especially the recently patented CoLD^® crystallization technology, provide additional options to power plants which are looking for methods to effectively and economically reduce or eliminate their water discharges from FGD scrubbers.

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 $125.00 for non-subscribers. Market Intelligence webinars are free to McIlvaine market report subscribers and are $400.00 for non-subscribers.

	2013
DATE	SUBJECT
August 15	Control and Treatment Technology for FGD Wastewater	Power
August 22	Pumps for Power Plant Cooling Water and Water Treatment Applications	Power
August 29	Status of Carbon Capture and Storage Programs and Technology	Power
Sept. 5	Fabric Selection for Particulate Control	Power
Sept. 19	Air Pollution Control for Gas Turbines	Power
Sept. 26	Multi-Pollutant Control Technology	Power
Oct. 3	Update on Coal Ash and CCP Issues and Standards	Power