FGD and Acid Gas Separation Webinar June 16, 2016
Program Details

Issues and options for SO₂ and other acid gas separation from coal-fired power, cement, steel, and waste incineration plants will be the focus June 16, 2016 at 10:00 a.m. central standard time.  

A collaborative format will be used to discuss decision guides on acid gas removal for coal-fired power, cement, steel, waste-to-energy, and glass plants. The decision guides already prepared on these subjects will be updated and briefly displayed during the meeting. We are inviting you to provide data on any new developments which should be incorporated.  Discussion will revolve around controversial issues such as

          General

• How do you determine the lowest total cost of ownership LTCO?
• Can U.S. and European suppliers leverage knowledge of the LTCO to penetrate markets in developing countries?
• How does the need to remove NO_x, PM, and mercury shape the decision on which acid gas removal system should be chosen?
• What efficiency improvements e.g. flue gas heat recovery are possible and how will that shape the acid gas decision?
• How do the needs differ between coal-fired power, cement, steel, and waste-to-energy?

      Dry Scrubbing

• How efficient is DSI?
• Where is sodium a better choice than calcium?
• What improvements are achieved by using special high reactivity hydrated lime?
• How widely will DSI be used in terms of which industries and which geographies?
• Is McIlvaine on the right track recommending an analysis of FIFO/LIFO to ensure that the first sorbent on the cake is pulsed and not the fresh unreacted sorbent?
• For medium sulfur coals, can a combination of DSI and a spray drier be competitive with circulating dry scrubbers?
• How much progress is being made on using DSI solid waste and converting it into bricks and building materials?
• Should every power plant using high sulfur coal consider DSI ahead of the air heater to reduce SO₃ and to be combined with an air heater upgrade to further reduce gas temperature?
• Can DSI with ceramic catalytic filters replace all the other APC devices?

          Wet Scrubbing

• What about the European approach in waste-to-energy which includes two scrubber stages including one to capture hydrogen chloride and make 30 percent hydrochloric acid?
• Why not leach out rare earths with the acid?
• The Chinese are touting a technology similar to the rod deck scrubber for wet limestone SO₂ removal. How do rod decks and trays compare to spray towers in terms of lowest total cost of ownership?
• Can lime be competitive with limestone as a reagent based on lower capital cost and higher efficiency?
• Can lime or other reagents be used along with limestone?
• Is the double alkali approach worth considering particularly if you have a high magnesium lime and can make magnesium hydroxide?
• Where are the ammonium sulfate and sulfuric acid options attractive?
• Should powdered  limestone replace ball mills  (this is popular in china)
• How efficient should mist eliminators be?

Components

• Wet: Agitators, oxidation blowers, pumps, valves, fans, hydrocyclones are all subject to severe service. How should these be designed to provide  LTCO?
• Dry:  Rotary atomizers, two fluid nozzles, slakers, dust valves are all in severe service. What selections provide the LTCO? How site specific is this in terms of coal type and sulfur percentages?

Materials

• Should linings or high alloys be used for scrubber shells?  How dependent is this on lining skills and site specific conditions

• Where should weld overlays and hard coatings be applied to pumps and valves?

Consumables

• What is the quality and availability of lime and limestone in each country?
• Should membrane or nonwoven bags be selected?
• What is the role of treatment chemicals in the fuel, flue gas and wastewater?

Click here for more information and to register

Complex Unintended Consequences Obscure the Path Forward for Air Pollution Control

A small Ohio town no longer exists thanks to the unintended consequences of air pollution control. A nearby power plant spent hundreds of millions of dollars to reduce NO_x.  The catalyst not only reduced the NO_x it converted SO₂ to sulfuric acid.  Within a few days, the acid deposition did such great damage to the buildings in the town that the utility agreed to buy the complete town and pay for relocations.  In the ensuing decade, catalyst suppliers have redesigned their product to eliminate this problem.

New mercury regulations have such low emission limits that the instrument just to measure gaseous mercury can cost hundreds of thousands of dollars. Prior to issuing the regulation, EPA tested a number of stacks and found that all the mercury existed in gaseous form.  Therefore, the regulations only required measurement of gaseous mercury.  In response to the regulation requirements, power plants, cement plants and waste-to-energy plants embraced a two-step solution.

Step one was to convert the gaseous mercury to particulate mercury.  Step two was to remove the particulate mercury.  The end result is that if step one is very efficient and step two is not, there is lots of particulate mercury being emitted.  Another unintended consequence is that particulate mercury will not travel far, whereas gaseous mercury can transverse the globe.  Even though this problem has been evident for a few years, there is still no proposed change in the regulations.

The recent regulation of many pollutants combined with new technology which makes it possible to remove all the pollutants in one device has greatly increased the use of fabric filters. However, there has not been a recognition of what McIlvaine describes as “The importance of FIFO vs. LIFO in Dust Cake creation.”

Direct sorbent injection (DSI) and embedded catalyst dictate a new approach to bag cleaning.  In addition to discrete particle capture, bag filters are being tasked with:

• Mercury removal
• Acid gas absorption
• Dioxin destruction or capture
• NO_x reduction

The importance of the method of bag cleaning can be illustrated by use of the accounting approach to inventory. Two options are first in first out (FIFO) and last in first out (LIFO).  If the price paid stays the same, the choice between the two accounting methods makes no difference.  But, if the cost of recent inventory is greatly different than the past, then the accounting method makes a big impact on profits.

The capture of discrete particles is the equivalent of price parity.  Let’s say that when you pulse a bag you are always discharging the latest particles to arrive and the remaining cake consists of the earliest. Since the ability of a matrix of dust particles to act as a filtration medium does not change, it does not matter which particles remain.  In fact, maintaining a somewhat permanent layer of cake protects the fabric from wear.  Also a more permanent cake provides higher dust capture.  It has been shown that on-line cleaning results in some re-deposit of dust particles.  But this is does not impact discrete particle capture efficiency.

The new paradigm with DSI is a big price difference. The newly arrived lime particle has the capability to absorb acid gases. The lime particle deposited earlier is already converted to calcium sulfate and provides no additional absorption capability. The semi-permanent cake layer is very undesirable for acid gas capture. Mercury re-emission is also a risk for an activated carbon cake which is semi-permanent. So it is very important to adopt FIFO and not LIFO.

This leads to the obvious question as to which are the best cleaning methods to achieve LIFO?  The long running debate about surface filtration vs. depth filtration needs to be reviewed in light of FIFO.  Also, the pulsing method itself needs to be reviewed.  Do some methods result in more re-entrainment of particles in the previous cake than do others?  Should more of the cake be removed with each pulsing?

It could be argued that the reaction takes place in the ductwork and not on the bag.  But the big difference in performance of bag filters vs. precipitators with DSI proves that the cake absorption is substantial.

There may be lots of research on this subject but if so, McIlvaine would appreciate feedback on it.  If there is not, it is an area deserving lots of attention.

Bag cleaning is also made more challenging by the increasing use of ceramic filter elements. The advantage of these elements is the ability to remove dust at 850°F.  The older generation rigid ceramic has been replaced by ceramic fiber media which can be pulsed.  However, this media cannot necessarily be pulsed with the identical system used for synthetic bags. An alumina refinery in Australia was having cleaning problems with a ceramic filter. Pentair Goyen analyzed the situation and provided a more robust pulsing system. This solved the problem.

Ceramic, glass and even synthetic media are incorporating catalyst in the media to reduce NO_x or oxidize dioxins. Do these designs require a different cleaning approach?  The catalyst in the Clear Edge design is not on the surface.  So, the dust cake will not affect performance except if it causes maldistribution of the gas.  If more gas flows through one area than another, the reactivity of the system is reduced.

A broader subject is the whole approach to cleaning. High pressure/low volume is the most popular option. Does capture of these other pollutants open the door for high volume /medium pressure or even for reverse air cleaning? 

The potential for the one-stop shopping is great.  Costs of pollution control can be reduced for new installations.  The small footprint makes a big difference in the cost of upgrading existing plants to meet new air pollution rules.  It is, therefore, important to understand and then maximize FIFO potential.  McIlvaine will be interviewing experts in the various niches to shed more light on this.  The results will be published in:

1ABC Fabric Filter

3ABC FGD and DeNOx Knowledge Systems

44I Power Plant Air Quality Decisions (Power Plant Decisions Orchard)

Industrial Air Plants and Projects

For information on how to participate contact: Bob McIlvaine at 847-784-0012 ext. 112 rmcilvaine@mcilvainecompany.com.

Utility E-Alert Tracks Billions of Dollars of New Coal-fired Power Plants on a Weekly Basis – May 27, 2016

Here are some headlines from the Utility E-Alert.

UTILITY E-ALERT

#1273 – May 27, 2016

Table of Contents

COAL – WORLD

§  First 800 MW Supercritical Thermal Power Plant in Karnataka, India Commissioned

§  EPH bids for Rybnik Coal-fired Power Plant in Poland

§  Doosan Babcock wins Contract for Biomass Conversion of Coal-fired Power Plant in UK

§  Egyptian Power Plant orders 27 KSB Pumps

The 41F Utility E-Alert is issued weekly and covers the coal-fired projects, regulations and other information important to the suppliers. It is $950/yr. but is included in the $3020 42EI Utility Tracking System which has data on every plant and project plus networking directories and many other features.

 HOT TOPIC HOUR (HTH) SCHEDULE

Click here to Register for the Webinars

FGD and Acid Gas Separation - Issue and options for SO₂ and other acid gas separation from coal fired power, cement, steel, and waste incineration plants.     
Click Here to Register

This free webinar will be held at 10:00 a.m. on June 16.  A collaborative format will be used to discuss decision guides on acid gas removal for coal fired power, cement, steel, waste to energy, and glass plants.  The decision guides already prepared on these subjects will be updated and quickly displayed during the meeting. Discussion will revolve around controversial issues. Subscribers to Power Plant Air Quality Decisions and Industrial Air Plants and Projects can access the guides at any time.  End users also have access upon request. Information on new developments is continually solicited.  For questions contact Bob Mcilvaine at rmcilvaine@mcilvainecompany.com 847-784-0012 ext. 112.  To register click here  

LIFO vs. FIFO filter pulsing to maximize acid gas capture - Last sorbent on the cake is first removed. How do we change that to FIFO? Click here to participate in the preliminary analysis.

Direct Sorbent injection is becoming increasingly popular. Much of the acid gas is removed on the cake formed in the pulse jet filter.  It is critical that the unreacted or last in sorbent is not the first out. The LIFO vs FIFO accounting concept may apply.  Input on this subject is solicited from sorbent, dust collector, bag and valve suppliers.  Over the next few months we will assemble an analysis and decision guide on maximizing acid gas capture in the bag filter. A webinar will be scheduled for early Fall to discuss the findings. For more information contact Bob Mcilvaine at rmcilvaine@mcilvainecompany.com 847-784-0012 ext. 112

Molecular Sieve Switching Valves

Molecular sieves are used to dehydrate gas. The valves used in switching from one sieve bed to another are subject to severe service including zeolite particles and corrosive, hot conditions. There is considerable controversy on the best valve designs and materials choices. Over the next few months we will assemble an analysis and decision guide on this subject. The preliminary analysis is provided at Severe Service Valve Technologies and Markets.  A webinar will be scheduled for early Fall to discuss the findings. For more information contact Bob Mcilvaine at rmcilvaine@mcilvainecompany.com   847-784-0012 ext. 112 

Choke Valve Decision Guide and Webinar

Mcilvaine is compiling a continually updated Decision Guide for operators of choke valves used in oil and gas and other industries for fluid control. Contaminants such as sand integrated into varying mixtures of water, oil, methane and other gases provide both operational and maintenance challenges. The guide will identify the major applications and then the performance of various designs and various materials for specific conditions. The Guide will be the basis of a recorded discussion to be conducted in early fall 2016.  The guide will be offered free of cost to any end user.  It will also be published in Industrial Valves: World Markets and Strategies.  The wisdom of the industry is sought in order to make this guide the best it can be.   Input is welcomed from any and all sources. White papers, articles and other data to further the discussion would be most helpful. The background information and part of the analysis has been prepared and is displayed at Choke Valve Decision Guide. For more information contact Bob Mcilvaine at rmcilvaine@mcilvainecompany.com847-784-0012 ext. 112. 

Details on Webinars

McIlvaine conducts periodic webinars which are in a discussion format and are free of charge to all participants. The displayed material and recordings are free to purchasers of the products and services and by subscription to others.

Format:  50-90 minute recorded discussion using McIlvaine display material. The session will be free of charge to all participants but registration is required.

Approach: There are two types of webinars. One is focused on Markets and directed to suppliers. The other is focused on aiding purchasers make the best Decisions relative to purchases of flow control and treatment equipment and services.

Markets HTH
General overviews of the market including size and major variables will be discussed with heavy emphasis on technology and regulatory drivers. The presentation will be based on the latest information appearing in Mcilvaine multi-client reports. Questions and views from both subscribers and non-subscribers are encouraged.

Decisions HTH
McIlvaine has been publishing information systems on pollution control since 1974. Each subject is organized by the pollutant control technology e.g. fabric filter, scrubber etc. There are search capabilities to retrieve information on any application. The newest addition has been slide deck systems displaying the issues and options relative to a specific applications. Coal-fired power, cement, steel, and waste combustion decision slide decks are continually updated.

The continually updated slide decks are displayed on the applicable Decision System.  It is recommended that participants view the slide deck in advance of the session and be prepared with questions and views.

Value to purchasers and specifiers:  Your questions and interests will be prioritized in the discussion. You will get a monthly newsletter and have continuing access to the system and multiple ways to interface in the future along with a networking directory of suppliers.

Value to Suppliers:  You have the opportunity to provide data to be considered at no charge. If you are also a subscriber you will see the summaries in advance and be able to shed light on issues and options not properly covered in the slide deck.  If you are a subscriber you will receive the monthly newsletter and continuing yearly access to the system including networking directories.

44I Power Plant Air Quality Decisions  includes 1ABC, 3ABC, 4ABC, 9ABC decision services but not 2ABC. So those with multiple technologies and at least partial focus on power will find this combination most cost effective. 

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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
www.mcilvainecompany.com