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WELCOME
Weekly selected highlights in flow
control, treatment and combustion from the many McIlvaine publications.
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Briefs
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True Cost of Gas Turbine Inlet Filters
·
True Cost of Limestone FGD Recycle Pumps
Briefs
The combust, flow, and treat (CFT) products and services markets will
exceed $400 billion next year. The market has typically been segmented by
McIlvaine on geographical end use. However, this analysis is based on where
the profits are generated. India and Italy are major exporters of valves.
Africa will enjoy a rapidly increasing market, but China will be one of the
main beneficiaries in terms of CFT products and services. It is building
complete power plants and mines and, in many cases, taking part ownership
of them. The market in 2030 is likely to rise to just under $600 billion if
there is a lack of government interference. However, if there is
interference in the markets the revenues could only rise to $535
billion.
Effect of Interference
on the Combust, Flow, and Treat Markets
Additional news you might have missed can be reached with the links
below.
Would You Rather Share Sales Leads with Your Allies or with Your
Competitors?
Sales Program based on the 500 Coal Plant Operators that buy 99
Percent of the Combust, Flow and Treat Products
Join the Debate on Insitu Rare Earth Recovery
True Cost of Gas Turbine Inlet Filters
The McIlvaine
Company is working with associations, media and suppliers to create true
cost analyses of combust, flow and treat products and services. One such
initiative is the “True Cost of Gas Turbine Inlet
Filters”.
The true cost
of a gas turbine inlet filter can be affected by a large number of factors.
These factors are not constants but are changing. The filter purchaser is
challenged to not only identify these factors but to keep up with the
changes.
Large gas
turbines are used to generate electricity by utilities. Smaller gas
turbines drive pumps and compressors in locations with extreme conditions
such as desert dust, artic snow or sea spray on an oil rig. As turbines
have become more efficient, they have become more susceptible to damage
from contaminants in the combustion air.
This ambient air from the surrounding environment can contain high
dust loads. In California with very
tight emission standards the particulate in the inlet air to the turbine can exceed
emission limits. Thus the gas turbine has to act as an air cleaning device.
The challenge
for gas turbine inlet fiber, media,
and filter suppliers is to increase gas turbine availability in all
environments with newer and more sensitive gas turbines. The newer turbine
designs are negatively impacted by small particles. This has led to the use of HEPA filters
with efficiencies classed as H10/E10 and higher. Studies show that turbine maintenance can
be reduced with even higher efficiency E12-U17. One study showed that even
if the cost of higher efficiency filtration were four times higher than
lower efficiency filters, the true cost would be lower.
One can choose
a system with non-cleanable filters. They are relatively inexpensive but
require continuous filter replacement.
By using a sequence of inefficient but inexpensive pre filters and a
final high efficiency filter, the replacement cost can be minimized.
An alternative
is to use a cleanable filter. Periodic air pulsing knocks off accumulated
dust. These systems are available
from many suppliers if the F-9 efficiency is all that is desired. Cleanable filters with H12 efficiency are
available from only a few suppliers.
On the other hand there are many new developments which will expand
the number of choices.
In terms of
high efficiency dust capture mechanisms there is a choice between wet laid
glass and synthetic nanofiber non-woven laminates or membranes. The
traditional glass media for HEPA filtration has been used primarily in
non-cleanable filters.
Quantifying
the benefit is a balance between reduced fouling and increased pressure
drop. The increased pressure drop can be estimated to restrict performance
by approximately 0.4%, while cutting fouling provides a 1.2% improvement in
output (empirical average). Therefore, the overall result is a potential
efficiency improvement of 0.8%.
http://www.mcilvainecompany.com/GTairTech/Subscriber/Default.htm
Alliance Pipeline believes that the E12 filters from Gore
may allow Alliance to extend the interval between overhauls of its aero
engines from 25,000 to as many as 50,000 hours (from three to six years).
The many
factors and media choices impacting gas turbine inlet filter selection have been discussed in a background
document on display at
http://www.mcilvainecompany.com/Decision_Tree/subscriber/Tree/DescriptionTextLinks/Gas_turbine_inlet_filter_decision_guide_april_26830.pdf
In the past the most efficient filters which were
used on gas turbine inlets were rated F-9 with efficiency of more than 95%
on particles 0.4 um diameter. The
most penetrating particle size is about 0.2 um where the efficiency is much
lower. Higher efficiency filters are
rated based on the most penetrating particle size as follows.
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HEPA Class
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Retention (total)
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E10
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> 85%
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E11
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> 95%
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E12
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> 99.5%
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H13
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> 99.95%
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H14
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> 99.995%
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U15
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> 99.9995%
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U16
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> 99.99995%
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U17
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> 99.999995%
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Membrane
laminates such as used for dust collection can meet efficiencies up to
E12. The question is whether this is
sufficient?
There are a
number of new filter and media designs which need to be evaluated. Mann & Hummel Vokes introduced the Aircube Pro Power S
which utilizes a new synthetic base media with much higher resistance to
mechanical stress than glass fiber media and a stable high efficiency
during operation. It is water and salt repellent while being extremely
robust.
DHA filter has introduced a cleanable HEPA filter for gas
turbine inlets which it will be displaying at PowerGen
The Guide to True
Cost of Gas Turbine Inlet Filters will be used to facilitate discussions at
a number of events in the coming months. It will be used along with a tour
guide on the subject at the PowerGen
exhibition in November.
http://www.mcilvainecompany.com/PowerGen_2019/Power-Gen_2019_Information.pdf.
It will also
be the subject of a discussion at FiltXPO which will be held in Chicago in
February.
The Decision
Guide is continually updated and included Gas Turbine and Reciprocating
Engines Decisions http://home.mcilvainecompany.com/index.php/silobusters/59d-gas-turbine-and-reciprocating-engine-decisions. It
is free of charge to gas turbine and engine owners and funded through
supplier subscriptions.
To participate
in the True Cost of Gas Turbine Intake Filters contact Bob Mcilvaine at rmcilvaine@mcilvainecompany.com
direct 847 784 0013 cell 847 226 2391.
True Cost of Limestone FGD Recycle
Pumps
The McIlvaine
Company is working with associations, media and suppliers to create true
cost analyses of combust, flow and treat products and services. One such
initiative is the “True Cost of Limestone FGD Recycle Pumps”.
80,000 MW of
limestone FGD recycle pumps will be purchased in India over the next three
years. Over 1.5 million MW of these large pumps are continually being
operated at power plants around the world. Their true cost (total cost of ownership) is a
substantial percentage of the true cost for electricity production. One
reason is the choice of pump energy over fan energy.
It can be argued that scrubbers using less
recycling slurry but more fan energy are a better choice but the coal fired
power industry has standardized on the spray tower type of limestone
scrubber. For a 1000 MW scrubber the
recycled slurry will be as much as 200,000 gpm delivered to the top of a spray tower at
a 50-100 ft elevation. This slurry is an abrasive, corrosive combination of
gypsum, calcium sulfite and limestone particles along with some residual
flyash. The pumps are expected to
remain functional for 20 years or more.
The true cost
of the pump purchase is impacted by many factors
· System design: the piping design, pump location, valve
resistance, spray tower nozzle type, chloride bleed provisions, requirement
for spares and other factors
· Pump design including initial
efficiency, deterioration characteristics, and pump characteristics
· Energy consumption for the new pump
and during the cycle prior to repair
· Cost of energy
· Cost of repair parts and frequency of
replacement
· Cost for service
· Operational factors such as
maintenance quality, hours of operation per year etc.
· Downtime costs
· Labor rates
· Related costs such as greater use of
limestone or treatment chemicals with varying pump performance
India has
adopted specifications with minor modifications which were first written
decades ago for projects in the U.S. or Japan. A recent BHEL specification
for an FGD system in Bangladesh Is for two generators each 660 MW and each
unit with one FGD system. Each FGD system will be provided with five
recirculation pump (4 working + 1 standby) which are located inside the
Recirculation Pump & Oxidation Blower House.
The
specifications for the recirculating pump allow for rubber lining,
stainless alloys or silicon carbide materials in contact with the sulfite
slurry with a maximum of 27,000 ppm chlorides.
http://www.bhel.com/dynamic_files/tender_files/pdf/BIFPCL%20MAI%20%20FGD%20ARP%20R01.pdf
This worldwide
standardization of scrubber designs and pump requirements means that there
is ample evidence of true cost of the various pumps which have been
utilized and the ability to project true costs for future installations.
True cost is
impacted by the location where the pump is manufactured and the location
where the pump is repaired. It is also impacted by the service personnel
proximity and the option for remote monitoring and support.
Libra Fluid Equipment Co., Ltd is home based in China. It
was founded in 1999 and provides pumps and parts for various industries.
It supplies pump parts for any pump
where the patents have expired. It
supplies ceramic, alloy and rubber lined impellers. This has true cost
implications. The true cost of a pump purchased from any company without
recently patented parts may be reduced with the option of purchasing parts
from others such as Libra.
Parts and repair is a major true cost factor. Duechting
Pump manufactures pumps in Germany but has regional service centers around
the world. Is the true cost greater or the same for pumps supplied in the
U.S and Asia?
KSB is a German based company but purchased GIW and
manufactures pumps in the U.S.
Trillium has multiple manufacturing and service
locations.
Suppliers are being asked to provide true cost analyses
which will be published in Coal Fired
Power Plant Decision http://home.mcilvainecompany.com/index.php/silobusters/44i-coal-fired-power-plant-decisions.
This is a service which is free of charge to utilities around the
world.
The service already includes recorded webinars and case
histories of FGD pump performance compiled over decades. The Utility Tracking System identifies
every FGD system in the world and includes the pump supplier for many of
them.
This is a
continuing process. As suppliers gain additional evidence it can be
incorporated. The process is likened to a criminal trial where the supplier
is the prosecutor and the jury is the purchaser. The difference is that the
jury is periodically asked to review its decision based on new evidence
such as life of impellers and casings in this recent case history.
The scrubber recycle pumps in this plant have operated at a
flow rate of 1,310 cubic meters per hour (m3/h), 21.1 meters (m) of head
and 630 revolutions per minute (rpm) for nearly 20 years, requiring minimum
attention and service. Of course, the mechanical seals were exchanged from
time to time. Apart from that, four impellers, one casing cover and some
minor components were replaced. An additional 24 pumps are installed in the
second scrubber system and other applications in the plant.https://www.pumpsandsystems.com/pump-materials-wet-flue-gas-desulfurization
There should be separate true cost analyses for each
location. It is particularly
important to analyze the cost in India.
A good example is the analysis by SHI FW relative to wet vs dry
scrubbers for Indian power plants.
Sumitomo SHI FW has made a detailed analysis comparing CFB scrubbers to
wet limestone scrubbers without wallboard quality gypsum production.
The lower
quality of limestone available, the expected 15-year life for the older
plants to which the system may be applied, and the much lower capital cost
of the CFB design are key aspects in the determination. Here are the
factors and calculations for a 300 MWe pulverized boiler contained in
the linked paper.
http://home.mcilvainecompany.com/images/Article_Show_me_the_Money_CFBS_vs_Wet_FGD_Aug19.pdf
The analyses are being pursued with personal discussions including at the upcoming PowerGen in New Orleans -
http://www.mcilvainecompany.com/PowerGen_2019/Power-Gen_2019_Information.pdf. There will be a PowerGen University
half day session on Monday where McIlvaine will advise suppliers interested
in reaching the international market to prepare detailed true cost analyses
of their offerings. There will also be a tour guide. Speakers, exhibitors,
and attendees interested in FGD recycle pumps will be listed in the
directory with emails and mobile phone numbers to facilitate discussions
during the conference.
For more information on Coal Fired Power Plant Decisions click on http://home.mcilvainecompany.com/index.php/silobusters/44i-coal-fired-power-plant-decisions.
To participate in the True Cost of
Limestone FGD Recycle Pumps contact
Bob McIlvaine at rmcilvaine@mcilvainecompany.com
direct 847 784 0013 cell 847 226 2391.
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