Materials for Corrosion Prevention in Power Plant and Boiler APC Systems is
Hot Topic Hour on August 9, 2012
Preventing and controlling corrosion has always been a challenge for power plant
designers and operating personnel. Corrosion occurs in virtually every component
of the typical coal-fired power plant from the material handling systems, the
boiler and ducts to the auxiliary systems for heat recovery and the SCR,
scrubbers, ESPs and baghouses for pollution control all the way to the stack as
well as the wastewater treatment system. Corrosion is both a chemical process
and a physical mechanism. The chemical composition of the coal (chlorine and
sulfur content) and additives to control pollution and wastewater affect the
potential for corrosion. The distribution of gases in ducts as well as
temperature, water content and particulate load contribute to mechanical flow
corrosion caused by abrasion and build up of corrosive materials in a specific
place in a duct or vessel.
Over the years, many methods have been developed to fight corrosion. These
include a variety of new materials for ducts, liners, tubes and even pumps and
valves, flow modeling and duct designs to minimize flow corrosion and injection
of chemicals to control acid gases. Perhaps the single most important issue is
to initially select the correct material for each application based on the
environment that it is expected to operate in. During the last decade, FRP
composites have become very popular for use in scrubbers, tanks, pipe and stack
liners because of their inherent resistivity to acids and lower cost compared to
exotic metals. However, with the cost of FRP polymers going up and with the
price of oil expected to continue rising in the future, is FRP still the best
choice? Are metals, ceramics or glass now a better choice? Which material is
best for each specific component in each air pollution control device?
The following speakers will discuss the latest developments in materials for
corrosion prevention or reduction from the boiler through the stack at a typical
coal-fired power plant with a focus on selection of materials based on plant
specific site conditions, capital cost, maintenance and life time. Speakers may
also provide an update of the current developments, on-going testing or
performance of installations of corrosion resistant materials or new technology
being developed at their respective companies.
Jim Ness, Corrosion Market Specialist at AOC Resins LLC
Doug Reinke, VP Sales & Marketing for Augusta Fiberglass (AFC), will discuss the
supply of FRP and dual laminate process equipment to all major process
industries. Over the last ten years, innovative equipment delivery methods have
been developed and refined to enable large FRP and dual laminate equipment to be
supplied to the power industry. The solutions have benefited the power industry
with safer and faster installations and better corrosion resistant equipment
that saves schedules, budgets, on-site work hours and life cycle costs. Doug
will review these delivery methods and applications.
Debajyoti (Deba) Maitra, Product and Application Development Engineer at
Huntington Alloys Division of Special Metals Corporation, will present
"Accelerated Crevice Corrosion of Duplex Stainless Steels in Wet Limestone FGD
Environments." A variety of steels and alloys have been used in the construction
of wet FGD air pollution control systems ranging from duplex and austenitic
stainless steels to highly alloyed grades of nickel-base corrosion-resistant
alloys. Many absorber vessels constructed of duplex stainless steel have
experienced severe corrosion, often after less than one year of operation. This
attack was explored and both laboratory and field tests were conducted.
Localized corrosion, especially under mineral deposits, was detected and
evaluated. Samples of several grades of stainless steels and alloys were exposed
in an operating scrubber vessel to determine their response to the conditions
experienced in the FGD system. While the attack of the duplex steel continued,
super-austenitic stainless steels and some nickel-base alloys were found to be
resistant. It is also likely that contaminants in the coal may be accelerating
the corrosion.
Lake H. Barrett, Sales Manager for Sauereisen, will discuss both tried and true
as well as state of the art corrosion resistant solutions for the protection of
concrete and steel structures in today’s power generation stations. His
presentation will incorporate both organic and inorganic technologies and cover
solutions utilized across the globe in air pollution control systems.
To register for the “Hot Topic Hour” on August 9, 2012 at 10 a.m. Central Time,
click here:
http://www.mcilvainecompany.com/brochures/hot_topic_hour_registration.htm.
McIlvaine Hot Topic Hour Registration
On Thursday at 10:00 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 Environmental
Upgrade Tracking System. The cost is $125.00 for non-subscribers. Market
Intelligence webinars are free to McIlvaine market report.
DATE Non-Subscribers Cost SUBJECT Webinar Type
August 9, 2012 $125.00 Materials for Corrosion Prevention in Power Plant and
Boiler APC Systems Power
August 16, 2012 $125.00 Report from Coal-gen (highlights of speeches and
exhibitions) Power
August 23, 2012 $125.00 Report from Mega Symposium (highlights of speeches and
exhibitions at this important air pollution conference) Power
August 30, 2012 $125.00 Pumps for Power Plants, Boilers and Water Treatment
Facilities Combined Cycle Plants Power
September 6, 2012 $125.00 Production of Fertilizer and Sulfuric Acid at
Coal-fired Power Plants Power
September 13, 2012 $125.00 Instruments and Technology for On-line Boiler
Monitoring Power
September 27, 2012 $125.00 Coal-fired Boiler Optimization Power
October 11, 2012 $125.00 Air Preheaters & Heat Exchangers Power
October 18, 2012 $400.00 Instrumentation for air, gas, water, liquids
(forecasts, market shares, growth segments) Market Intelligence
October 25, 2012 $125.00 Cooling Towers and Cooling Water Issues Power
November 1, 2012 $125.00 FGD Scrubber Components Power
November 8, 2012 $125.00 Dampers and Expansion Joints for Coal-fired and Gas
Turbine Power Plants Power
November 15, 2012 $125.00 Catalyst Selection for NOx and Other Gases Power
November 29, 2012 $125.00 Boiler Feed and Cooling Water Treatment Power
December 6, 2012 $125.00 Co-firing Sewage Sludge, Biomass and Municipal Waste
Power
December 13, 2012 $125.00 Update on Oxy-fuel Combustion Power
January 10, 2013 $125.00 Material Handling in Coal-fired Power Plants Power
January 17, 2013 $125.00 Gypsum Dewatering Power
January 24, 2013 $400.00 Filter media (forecasts and market drivers for media
used in air, gas, liquid, fluid applications, both mobile and stationary) Market
Intelligence
January 31, 2013 $125.00 Valves for Power Plants, Boilers and Water Treatment
Facilities Power
The Market for Catalytic and Thermal Treatment Will Grow to $22 Billion Next
Year
The markets to oxidize pollutants from stationary and mobile sources will grow
more than 8 percent in 2013 to $22 billion. This is the latest forecast in the
McIlvaine report, Thermal/Catalytic World Air Pollution Markets published by the
McIlvaine Company.
There are three market segments. One is mobile sources, another is stationary
engines, and the third is industrial processing. In general, all the technology
involves ensuring oxidation either through temperature increase or a combination
of more modest increase in the presence of a catalyst. The advent of NOx
regulations has introduced another principle labeled reduction. A nitrogen
compound such as urea reacts with NOx to form elemental nitrogen and water.
The forecasts also include the particulate filters necessary to minimize soot.
This forecast includes the NOx reduction from mobile sources but not the NOx
reduction from industrial processing which is included in another McIlvaine
report.
Industrial processors have four equipment options. One is conventional thermal
treatment. Another is catalytic treatment. A third equipment type is labeled
regenerative thermal oxidizer. The big advantage of this approach is heat
recovery. A fourth type is a hybrid which incorporates both the catalyst and the
regeneration.
The industrial market not including replacement catalyst will generate revenues
of just over $2 billion next year.
Industrial Thermal Treatment Revenues ($ Millions)
Continent 2013
Africa 49
America 577
Asia 896
Europe 536
Total 2,058
Asia, with its industrial expansion, will be the continental leader with
purchases of just under $900 million.
The mobile market will benefit from a rebound in vehicle sales and tightening
regulations. A number of countries have adopted schedules for phasing in PM
emission standards for heavy-duty diesel engines that are likely to require
advanced after treatment to meet the relevant national standard. In the
Americas, Brazil’s PROCONVE P7 standards beginning in the 2012 model year are
likely to require advanced after treatment. Urea consumption for the heavy truck
market in Brazil will grow substantially from a disappointing total of around
$15 million this year.
Russia has adopted standards based on EURO IV starting in the 2010 model year
and standards based on EURO V in the 2014 model year. In the Beijing area, China
adopted standards equivalent EURO IV in 2008, and has proposed adoption of EURO
V- equivalent standards in 2012. In addition, several countries that have
applied for membership in the European Union will adopt EURO standards if
accepted.
Platinum and palladium prices are expected to increase this year as a rebound in
U.S. automobile sales boosts demand for the metals used in catalytic converters.
Rhodium prices which slumped 38 percent in the past twelve months are predicted
by some analysts to increase 62 percent to $2,000 an ounce by the end of 2013.
The stationary engine market will grow robustly in the next few years led by the
U.S. Nearly one million existing, stationary diesel engines are affected by new
federal air quality rules, in addition to more than 300,000 gasoline, propane
and natural gas engines, including thousands of engines in the Hawaiian Islands.
The new RICE National Emissions Standards for Hazardous Air Pollutants (NESHAP)
rules affect engines used for generators, pumps, compressors and other common
plant equipment. The requirements’ full compliance date is May 3, 2013 for
diesel (CI) engines and October 19, 2013 for gasoline and natural gas (SI)
engines.
For more information on Thermal/Catalytic World Air Pollution Markets
http://www.mcilvainecompany.com/brochures/air.html#n007.
Here are the Headlines for the July 27, 2012 – Utility E-Alert
UTILITY E-ALERT
#1085 – July 27, 2012
Table of Contents
COAL – US
EPA agrees to reconsider its Mercury Standards for New Power Plants
Dairyland Power will install Pollution Control Equipment at Alma and Genoa
Appeals Court Upholds Short Term SO2 Limits
Sierra Club to sue Puget Sound Energy over Alleged Colstrip Violations
Southern Company to shut down 4,000 MW of Older Power Plants
Petitioners ask for Review of Ozone Nonattainment Areas
Neumann Systems Scrubber for Colorado Springs Martin Drake is Back on Track
Neumann Systems may Extract Rare Earth Metals from Flyash
Texas Judge blocks Air Permit for Las Brias Coal-fired Power Plant
COAL – WORLD
CEZ to sell Pocerady and Chvaletice Power Plants
Ukraine to switch Severodonetsk from Gas- to Coal-firing
Alstom to retrofit Low Pressure Turbine at Rostock, Germany
Exxaro proposes 1200 MW Power Plant near Lephalale in Limpopo, South Africa
Odisha and Kerala plan 1000 MW Mine-mouth Power Plant in Angul District,
Orissa, India
India to require Washed Coal for Power Generation
Huadian to build 500 MW Rovinari in Romania
Siemens to deliver Power Islands to POSCO in Korea
NTPC allotted land at Sandni and Baraithi (Madhya Pradesh, India) for 6x660 MW
Power Plant
Funding cancelled for Latrobe Valley IGCC Power Plant
NTPC and JSEB will build 1320 MW Power Plant
Enerjisa has Loan for 450 MW Tufanbeyli Power Project in Turkey
GAS/OIL US
NRG’s 558-MW Carlsbad Power Project can proceed
GAS/OIL WORLD
Alstom to renovate 657 MW Jhanor Gandhar in Gujarat, India
BIOMASS
Drax plans to convert Three Boilers to 100 Percent Biomass-firing
GASIFICATION
Chicago Clean Energy Project Provides Environmental Benefits
HOT TOPIC HOUR
Beneficial Byproducts from Coal are Important – Take-away from the Hot Topic
Hour July 26
“Mercury Control and Removal Status and Cost” is Hot Topic Hour on August 2,
2012
Upcoming Hot Topic Hours
For more information on the Utility Environmental Upgrade Tracking System, click
on: http://www.mcilvainecompany.com/brochures/energy.html#42ei.
Biogas Plants Turn Waste into Energy
Biogas plants are gaining in popularity. As shown in the last article from
McIlvaine’s Renewable Energy Projects and Update so much so that one
manufacturer is building a new manufacturing plant.
Weltec Biogas Park Construction Starts in Arneburg
Weltec Biopower started building one of Germany’s largest biogas plants in
Arneburg, Stendal District, Saxony-Anhalt. At this plant, about 6 million m3 of
biomethane (more than 700 m3/h) will be produced every year in four fermenters,
six digestate storage units, and one liquid reservoir and will be fed into the
natural gas grid.
“This biogas refinery, which will start feeding in its first biomethane in
December 2012, will create about ten permanent jobs and two training positions,”
says Jens Albartus, Director of Weltec Biopower GmbH.
The sustainability concept of the plant that is being erected on a site of about
6 hectares provides for the use of renewable raw materials and manure from 30
farms. Among other things, it was made sure that the farmers who will also use
the digestate do not need to travel more than 9 miles, on average, to deliver
the substrate.
The biogas will undergo amine treatment. The generated biomethane will be
sufficient to supply about 5,000 households with power and heat or 4,200 cars
with an annual mileage of about 18,000 miles.
Apple Plans 5 MW Biogas Fuel Cell Plant
Apple plans to power its Maiden, NC, data center with biogas. The facility will
consist of 24,200 –kW alternating current all-electric fuel cell systems.
The fuel cells use methane produced by animal waste, and converts that to
electricity. Apple’s installation will be built by California’s Bloom Energy,
and it will be the largest such fuel cell installation built outside of the
utility industry
Lockwood Landfill to Produce 3.2 MW of Electricity Using Landfill Gas
Waste Management opened northern Nevada’s first and only Gas-To-Energy power
plant at its Lockwood Landfill, which will use landfill gas produced onsite to
generate electricity. The project will create enough renewable energy to power
more than 1,800 homes.
When organic materials, like food and yard waste, decompose, they create a gas
comprised of about 55 percent methane. Collection wells placed all over the site
collect this gas and then pipe it to the power plant, where it is used as a fuel
to run two generators. The project, which went online in March, will offset the
use of about 700 railcars’ worth of coal.
SMUD and SRCSD Team to Develop Region’s First Co-digestion Facility
The Sacramento Municipal Utility District (SMUD) and the Sacramento Regional
County Sanitation District (SRCSD) have begun construction of a co-digestion
facility as part of the region’s renewable energy efforts. The facility will
provide a new local disposal option for wastes such as fats, oils, grease (FOG)
and liquid food processing waste.
SMUD and SRCSD received approximately $1.45 million in American Recovery and
Reinvestment Act funding from the United States Department of Energy and
$100,000 in matching funds from the California Energy Commission to help
construct the facility at the Sacramento Regional Wastewater Treatment Plant
(SRWTP) in Elk Grove. The remainder of the project will be funded by SRCSD. The
construction cost of the FOG receiving station is approximately $2.1 million.
The project will increase the production of biogas already being produced at
SRWTP by injecting waste materials directly into the digestion system, bypassing
initial steps that are currently depleting the energy value of the waste. The
additional biogas captured will be used by SMUD to generate renewable energy at
SMUD’s Consumnes Power Plant located in southern Sacramento County.
2G Group Announces a New Manufacturing Plant for Biogas CHP Power Generation
Systems in the U.S.
2G CENERGY Power systems Technologies Inc., a 2G Energy AG Group Company,
announced that it received more U.S.-based orders during the past few months
than during the entire fiscal years of 2010 and 2011 combined. Based on that
significant development 2G decided to establish a U.S. production facility in
St. Augustine, FL, where it will start to produce its advanced biogas combined
heat and power (CHP) clean energy conversion systems for all North and South
American markets. The decision is considered to be a major component of the
company’s overall U.S. strategy to enforce its customer service commitment,
further increasing its competitiveness, and rapidly growing its American
customer base.
2G-CENERGY in return saw an increase in sales and was selected as the supplier
of choice for a multitude of new projects between 250 kW and 3 MW. The 2G Group
effectively transformed the gained momentum from highly-satisfied customers
after 2300 installed biogas CHP systems, into new sales to private and public
organizations in the United States. Most of these projects are at dairy and
livestock farms, municipal waste management facilities, as well as wastewater
treatment plants and organic waste disposal sites in Wisconsin, Ohio, Michigan,
Illinois, Indiana, New York, Pennsylvania, Vermont, Maine, New Jersey,
Washington, Oregon, California and the Carolinas.
The company purchased a 60,000-square-foot facility in the St. Augustine
Interstate Commercial Park, located at the I-95/CR-20812 intersection, as well
as the adjacent lot for future expansion. The 10-acre site is perfectly located.
With the new plant, 2G will bring about 125 new jobs to the area, and will add a
significant number of career opportunities in related sectors. This decision
will also raise the overall 2G Group production capacity in anticipation of
solid growth and increased demand for advanced thermo-dynamical,
output-optimized biogas cogeneration CHP modules, with a high degree of
electrical and thermal energy efficiency. The production capacity for this new
facility will be gradually increased.
For more information on Renewable Energy Projects and Update please visit:
http://www.mcilvainecompany.com/brochures/Renewable_Energy_Projects_Brochure/renewable_energy_projects_brochure.htm
----------
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http://www.mcilvainecompany.com/brochures/Free_Newsletter_Registration_Form.htm.
Bob McIlvaine
President
847-784-0012 ext 112
rmcilvaine@mcilvainecompany.com
www.mcilvaine@mcilvainecompany.com
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191 Waukegan Road Suite 208 | Northfield | IL 60093
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