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WELCOME
Weekly selected highlights in flow
control, treatment and combustion from the many McIlvaine publications.
·
WEFTEC 2919 MBR and
Aeration Blower True Costs
·
Dry Scrubber
Pre-conference Webinar and Program
·
Does McKinsey Report on Flow Control Consider Asian
Suppliers?
·
Utility E Alert
Headlines for Last Week
·
LNG is a Most
Profitable Market for CFT Suppliers
WEFTEC 2919 MBR and Aeration Blower True Costs
Aeration Blower True Costs.
The exhibition stands and speeches will provide
substantial insights into the true costs of aeration blowers. A guide to each relevant exhibit and
speech has been prepared. A networking
directory to insure the most efficient interface with knowledge sources is
also provided. This guide is being
continually updated.
WEFTEC 2919 Municipal Wastewater
True Cost Guide
In order to facilitate the discussions an extensive
analysis Municipal
Wastewater Blower True Costs is being made available to
attendees. Feel free to submit case
histories and comments to add to the analysis.
Important questions are
· Which
blower type is best fitted for a specific application? high speed turbo,
screw compressor, rotary blower, or single stage centrifugal?
· Choice
of magnetic or air foil bearing design
· Drives,
controls
· Application
developments such as nitrification, process control
· Multiple
vs single blower
· Site
specific variables such as electricity cost, flow variation, plant life
To
contribute to the analysis and guide
contact Bob McIlvaine 847 226 2391 email rmcilvaine@mcilvainecompany.com
WEFTEC Municipal Wastewater Membrane Bioreactor True Cost Guide
The exhibition stands and speeches will provide
substantial insights into the true costs of
membrane bioreactors and components. A guide to each relevant
exhibit and speech has been prepared.
A networking directory to insure the most efficient interface with
knowledge sources is also provided.
This guide is being continually updated To view the contents
Click Here
To contribute to this guide contact Bob McIlvaine 847 226
2391 email rmcilvaine@mcilvainecompany.com
A market
report on membrane bioreactors is also available. For Details on the
report Click Here
The
very substantial body of information from WEFTEC 2018 is shared
at
Municipal Wastewater Treatment Update
Dry Scrubber Pre-conference Webinar and
Program
If you are involved with dry scrubbers. Here are four
knowledge sources
· DSUA
pre-conference webinar August 29th at 11:AM EDT
· Dry
Scrubber Users Conference September 10-12 in Kansas City
· SOx-NOx
2019, September 11-13 New Delhi India
· Coal
Fired Power Plant Decisions
DSUA Pre Conference Webinar
On August 29th at 10:AM central time, there
will be a preview of the DSUA conference with a presentation by Gerald
Hunt, DSUA president followed by discussions with panelists, Bob McIlvaine
and Paul Brandt of Burns & McDonnell. The question posed to the
audience will be how to leverage the conference and archives on a
continuing basis to assist in dry scrubber decision making worldwide.
An hour has been allotted to this discussion which is
free to anyone. To register for the meeting just email Ross Ardell at rardell@mcilvainecompany.com. Address questions to Bob
McIlvaine at 847 226 2391 email rmcilvaine@mcilvainecompany.com
Dry Scrubber Users Conference
This conference is unique due to the frank and in depth
discussions which take place. The focus is semi dry and dry scrubbers used
in a number of different industries. There are tours of dry scrubber
installations in the Kansas City area, speeches by end users and suppliers,
exhibits, and most importantly lots of opportunities to talk to the other
attendees. Details on the conference
are found at http://www.dryscrubberusers.org/
SOx-NOx 2019
Government and
industry leaders will be participating in this annual conference addressing
air pollution control needs for power plants. This market is the world’s
most active for FGD presently with utilities expected to install systems on
160,000 MW of capacity. Details are
found at http://soxnox2019.missionenergy.org/
Coal fired Power Plant
Decisions
Dry
scrubbing is one of the options used by coal fired power plant operators to
capture SO2, sulfuric acid mist and other acid gases. 44I
Coal Fired Power Plant Decisions provides
a forum for end users and suppliers to determine which pollution control
options are best for a specific plant. Because of lack of water, low SO2
concentrations, weak gypsum market demand, and other factors a dry
rather than wet scrubbing solution may be the best choice.
The
choice is made more complex by the need to address multiple pollutants. Dry
scrubbing is effective in removing SO3 whereas this is not
true of wet scrubbers. With the addition of activated carbon, dry scrubbers
can also remove mercury. There are multiple dry scrubber designs. Some are
better with higher sulfur levels. So the fuel becomes one variable in the
pursuit of the lowest total cost of ownership solution.
There
are multiple dry scrubbing technologies. One is the spray dryer absorber
(SDA). This utilizes the same principle used in manufacturing instant
coffee or powdered soft drinks. A slurry is sprayed into a vessel through
which the hot gas flows. The liquid evaporates. The acid gas reacts with
the absorbing particles. The particles are then captured in a fabric
filter.
The
circulating fluid bed (CFB) scrubber functions by passing the acid gas
through a fluidized bed of lime particles. Circulating Dry Scrubbers (CDS)
entrain and then separate the particles. Lime or sodium particles are
injected into the flue gas duct with Dry Sorbent Injection (DSI) systems.
The catalytic filter uses the DSI principle ahead of a ceramic filter
medium with embedded catalyst for both particulate control and NOx
reduction.
There
are a number of materials, fibers, media configurations and element designs
which are utilized. The collection media in the fabric filter has a major
impact on cost. The optimum gas velocity can vary depending on the media
selected. If the velocity can be doubled then the size of the unit can be
halved. Instead of 4000 bags for a big installation maybe only 2000 would
be needed.
On
the other hand, the cost of ownership is significantly affected by the bag
life. If bags last one year rather than four or five years, then bag costs become
a significant part of the total expense. The energy cost is also a factor.
Energy consumption increases in direct proportion to velocity. It also
increases in direct proportion to the thickness of the dust cake on the
filter media.
In
the case where only particulate is to be captured it is best to establish a
semi-permanent cake on the bags and then pulse off the new cake. In
accounting terms this is LIFO (last in first out). However, for dry
scrubbing it is best to remove the reacted gypsum and retain the fresh lime
(FIFO). The industry has not formally addressed FIFO vs LIFO and needs to
do so.
The
need to maximize acid gas capture and the resultant substantial increase in
particulate loading affects the choice of fibers and filter media. The type
of cleaning (reverse air or pulsing with compressed air) also determines
the selection of the lowest true cost medium.
The
fuel or product being calcined or treated also impacts the medium. If a
high sulfur fuel is burned, the costs of dry scrubbing are comparatively
higher than if a low sulfur fuel is burned. Various fibers react
differently to various combinations of acid gases, temperature and
humidity. One fiber may handle SO2 and HF in relatively
humid conditions at 300 F whereas another cannot.
Temperature
resistance is important for several reasons. One is that a fiber which can
withstand the temperature excursions will have a longer life than one which
is dependent on more perfect operation of the system. Another consideration
is the potential to recover heat.
An
alternative to glass and polymeric resins is a ceramic fiber matrix.
Elements can contain embedded catalysts. Dry sorbent injection ahead of the
ceramic media can be utilized to provide removal of dust and acid gases
while reducing NOx. The resultant clean hot gas at 600 F or
higher can then be directed to an efficient heat exchanger and most of the
potential energy recovered.
The
material, fiber design, media construction and filter element shape all
have to be designed to address the unique requirements of the application
and the technology being employed.
The
two major fiber types are glass and polymers.
|
Type of Fiber
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Glass
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Polymers
|
|
Construction
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Woven generally but also some
non-woven
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Non-woven
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Laminates
·
Laminate with Membrane
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Performance
varies both in terms of temperature, abrasion and chemical resistance.
|
Fiber
|
Type
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Max Continuous
Temperature
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Chemical
Resistance
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Abrasion Resistance
|
|
PPS
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Felted
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375
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Excellent
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Excellent
|
|
PTFE
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Woven
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450
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Excellent
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Fair
|
|
Fiberglass
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Woven
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450
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Good
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Fair
|
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P84
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Felted
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500
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Very Good
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Excellent
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There
are differences in laminates with multiple non-woven layers being employed
with varying support materials and designs. Fiber shape is also a variable.
How
complex are the decisions? There are at least 1500 combinations to assess.
But
there are also site specific considerations such as cost of electricity,
reagents, pollution limits, plant life, existing equipment. So these can
present another 100 variables resulting in 150,000 factors.
There
are mountains of information available on all the different variables.
Determining which information will help select the lowest total cost of
ownership product is a daunting task. The answer is “shared responsibility
and collaboration”. Organizations focused on components such as filter
media or reagents can contribute but only if there is a clear path on how
to do so. The Dry Scrubber Users Group which is focused on the subject in
the broadest terms can be the catalyst to help bring other organizations
into what can be titled a True Cost Program. The program can provide access
to the needed evidence for validation of lowest total cost of ownership.
Conferences and exhibitions can provide a forum for actual validation of
supplier claims. The categories include component related conferences as
well as industry conferences.
Shared
responsibility and collaboration are best driven by suppliers who are
convinced that their product has the lowest true cost and are willing to
help provide all the evidence pro & con to support their position. Coal Fired Boiler Decisions has a
Dry Scrubber Decision Guide, a monthly FGD newsletter and another
newsletter just on Fabric Filters. Information has been compiled for this
service for 45 years. Collaboration with publishers and conference
organizers includes dry scrubbing tour maps and networking at exhibitions.
Coal
Fired Power Plant Decisions is being offered free of charge to utility
operators. Suppliers are able to participate with just a $1600/yr
subscription. For more information click on 44I
Coal Fired Power Plant Decisions
Bob
McIlvaine can answer your questions at 847 784 0013 email rmcilvaine@mcilvainecompany.com
Does McKinsey Report on Flow Control
Consider Asian Suppliers?
A
new report by McKinsey, Flow
Control-Sector at a Cross Roads analyzes industry performance based on
Japanese, U.S. and European companies.
It considers a $225 million market which McIlvaine pegs at more than
$400 million.
If
the industry is at a cross roads it is likely to be based on the rise of Chinese,
Indian and other suppliers in the fastest growing parts of the globe. Larsen & Toubro is a major valve
supplier based in India. Neway is a major valve supplier based in
China. Sinopec, based in China, is the world’s largest flow and treat purchaser
but also a major supplier of pumps.
The
crossroads which McIlvaine maps is between regional and world focus. It is
from orientation around countries to orientation around worldwide users.
The oil, chemical, mining and other industries are using remote monitoring,
process management software, and data analytics to specify flow and treat
products for all their plants around the world. Suppliers need to adapt these developments. The following recent news releases
address the question in one way or another
Selling to
the 500 Coal Plant Owners who make 99 percent of the Purchases
Oil, Gas,
Refining Daily Project Tracking and Monthly Analysis
Factors
Shaping the Combust, Flow and Treat (CFT) Market
Innovation
in the Combust, Flow and Treat Industry is a Product of Wisdom through
Interconnection
Pump
Companies Continuing to Change Strategy and Ownership
Flow and
Treat Purchases by TSMC and Other Chip Producers
Flow and
Treat Acquisition Choices Shaped by Most Profitable Market Program
Bottoms Up
Collaboration Around Each Major Flow and Treat Prospect
Eliminating
Silos can Increase Profits in Air, Water and Energy
LNG is a
Most Profitable Market for CFT Suppliers
Most
Profitable Petrochemical Markets for CFT Suppliers
Treatment
Chemicals Most Profitable Market Analyses based on Knowledge
Utility E Alert Headlines for Last Week
Here are the headlines in the Utility E-Alert for last week. This service is available separately or
as part of a package Power Generation Markets and Projects
#1434 – August 16, 2019 Table of Contents
COAL – U.S.
·
How ACE affects today’s Utility Plants
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Coalition of US States and Cities
challenges Trump Coal Pollution Wind-back
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Coal Unit Trump wanted saved set to close
19 Months Early
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TVA seeking Public input on expansion of
Coal Reserves
COAL – WORLD
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Australian Utility flags early closure of
Brown Coal Plant
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Russian Coal Company seeking change to Big
Arctic Reserve Boundary
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Vietnam’s Prime Minister urges
construction of Two Coal Plants
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CEZ Group turns to Gore to reduce Mercury
Emissions from Melnik I
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36,000 Hours of operation for P84+PPS
Bags at Eskom
NUCLEAR
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NRC approves Sale of last Nuclear Plant in Massachusetts
INDIA
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Analysis of Indian FGD Suppliers
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Indian Coal Ash Dam collapses
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Indian Power Lobby presses for further
delay in Pollution Standards
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Doosan is active in India and Around the
World in the Full Range of APC Equipment
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Indure is a large Indian EPC Company with
APC Licenses
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BHEL is the leading Supplier of Power
Plants and FGD Systems in India
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ISGEC has Licenses from Multiple
International APC Suppliers
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GE is the Second largest FGD Supplier in
India
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Hamon Indian Subsidiary selling Cooling
Towers, Chimneys and Air Pollution Control Equipment in India
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Rieco offers a Limestone FGD System with a
Venturi Scrubber for Particulate removal
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Andritz offers Wet and Dry FGD Systems in
India
·
Larsen and Toubro designs Plants, Air
Pollution Control Systems and manufactures Components such as Valves
·
Circulating Fluid Bed Scrubber could be
the best choice for many Indian Power Plants
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Adage Automation supplies 127 CEMS for
Reliance Industries
·
Bids close for DSI for 4 x 210 MW of
DSI systems at Punjab State Power Roopnagar in September 2019
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Tata Power March 2019 bid request
for 1 x 67.5 MW DSI FGD System
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Carmeuse exporting Lime to India from Oman
·
Valmet uses the Condensing Scrubber
Technology to recover Heat
LNG is a Most Profitable Market for CFT Suppliers
Combust, flow, and treat (CFT) products are important
components in liquefaction of natural gas, the transport of those liquids
by ship or land and their regasification prior to use. It is desirable for
a CFT supplier to assess this opportunity based on the basis of the profit
which can be obtained by pursuing it. This Most Profitable Market (MPM) can
be defined as the market which yields the highest profit given the
resources available.
The LNG market creates high profit opportunities for CFT
companies due to
· High growth
· Challenging applications
· Relative few decision makers
· Purchaser desire to buy based on lowest total cost of
ownership
·
Ability to validate lowest total cost of
ownership
High Growth: High growth markets have less competition
and a bigger profit opportunity. LNG will be experiencing rapid growth.
Over the next few years the U.S. will lead in liquefaction construction.
Regasification facilities will be constructed in many countries. LNG
represents just under 10 percent of the global gas supply. LNG continues to
be the fastest-growing gas supply source. The expected world compound
annual growth rate is 4 percent a year between now and 2035. However growth
in the next 5 years will exceed 7 percent.
2018 liquefaction capacity was 370 million tons per annum
(mtpa). 875 mtpa of new liquefaction capacity is proposed. 92 mtpa is under
construction. Global regasification capacity is 851 mtpa. There are 478 LNG
vessels with more than 20 new vessels per year being commissioned. In 2023
Australian capacity will exceed 80 mtpa compared to 100 mtpa in Qatar and
65 million mtpa in the U.S. The U.S. will experience the fastest growth
from a base of 20 mtpa in 2017.
This
extract from the LNG analysis is similar to one on each oil, gas, refining,
and petrochemical sector in N049 Oil, Gas, Shale
and Refining Markets and Projects
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