Fuel Cost and Environmental Regulations are Causing Changes in Industrial
Boiler Design and Operation
There are many new industrial boilers being constructed in developing countries.
Those in existence in developed countries are being upgraded in accordance with
new environmental regulations and the availability of alternative fuels. A third
development is the more efficient capture of the energy produced. These are the
conclusions reached in Industrial Boilers. This is one of a number of segments
of the McIlvaine service Industrial Emitters. (www.mcilvainecompany.com)
The increasingly stringent regulations are creating a number of changes. China
has shut down thousands of small coal-fired boilers due to their SO2, NOx, and
particulate emissions.
In the next few months, operators of U.S. industrial boilers will have to decide
whether to gamble on low gas prices for the next two decades or add air
pollution control equipment to their existing systems. There are more than
10,000 boilers listed in the McIlvaine Industrial Emitters database and project
tracking system. Less than 2,000 will fall under the criteria for action set up
by the new Industrial Boiler MACT rule. Of these 2,000 units, only 500 units
will have to make major capital expenditures. These plants will have to decide
whether to invest the funds to meet the new regulations or switch to natural gas
or even retire the units and buy electricity. The Industrial Emitters program is
tracking these decisions as they happen.
Fuel cost and availability is a major cause of change throughout the world.
Europe has regulations on coal burning which require operators to also burn
biomass. As a result, European operators are paying as much as $100 /ton for
wood pellets from the U.S. and agricultural waste from South Asia. At the same
time that natural gas has become economically attractive in the U.S., it has
become unattractive in much of Europe. Recently, waste-to-energy plants in
Europe have started exploring the potential of importing treated garbage which
is labelled Refuse Derived Fuel (RDF) from the Americas and elsewhere.
Most industrial boiler installations provide steam for industrial processes.
Large chemical plants and refineries also generate their own electricity. There
remains untapped potential to integrate power generation, process steam and
supply of low quality steam for other applications. District heating is an
example of the way to extract the most energy from the fuel. In a typical
fossil-fired boiler, there is a cooling tower to condense the low pressure
steam. The large plume visible from these plants is testimony to the very large
amount of heat being lost. Several new processes can be integrated into
industrial complexes. One is the production of ethanol. The low pressure steam
from power generation can be utilized with major cost savings. One of the
fastest growing industries is Recirculating Aquaculture Systems (RAI). The
production of fish in carefully temperature and oxygen controlled tanks is
proving to be less costly than the traditional ponds. They can be located at
industrial facilities and be integrated with power production.
In addition to the cost benefits of cogeneration, there is the substantial
reduction in greenhouse gases. If an ethanol or RAI plant does not have to be
equipped with a boiler, there is a very substantial reduction in potential CO2
emissions.
For more information on Industrial Emitters, click on:
http://home.mcilvainecompany.com/index.php?option=com_content&view=article&id=93extsup1.asp
Lots of New Developments in $11.2 Billion World Market for Fabric Filters and
Bags
The market for bags will grow 6 percent this year to reach $2.9 billion in 2014.
The market for fabric filter systems will grow 4.4 percent to reach $8.9 billion
next year. These are the conclusions reached in World Fabric Filter and Element
Market published by the McIlvaine Company. (www.mcilvainecompany.com)
Fabric Filters and Bags Market $ Millions
Subject 2013 2014
Bags 2,706 2,866
Equipment 3,869 4,041
Media 1,524 1,617
Systems 8,512 8,890
The lower growth rate for systems is a function of the proportion of revenues in
developing countries. The system revenues per cfm (unit of gas volume) are lower
in these countries. The bag revenues are positively impacted by the move to
membrane laminates. This media is more efficient, but is also more expensive.
There are a number of major changes in the industry in addition to the
introduction of new materials. A number of Chinese bag makers are now making a
global presence. There is also movement within China to increase the purchase of
fabric filters as opposed to precipitators in the power and certain other
industries.
The industry is becoming internationalized on a continuing basis. Within the
last twelve months, Nederman purchased Mikropul, Pneumafil and Menardi. CECO
purchased Met-Pro. Nederman has a European base and is strong in small fabric
filters. Mikropul was the inventor of the pulse jet filter and has worldwide
presence in the process industries. CECO has acquired Flexkleen as part of the
Met-Pro acquisition. This will supplement its activities through its Fisher
Klosterman subsidiary. Donaldson continues to gain market share in Asia.
Media suppliers are very international. Roll goods are being manufactured by the
larger media suppliers in several international locations. Many media suppliers
have successful manufacturing operations in Asia.
New applications are expanding the market as well. The need to remove mercury
has resulted in combinations of activated carbon injection followed by fabric
filters. This requirement is going to expand the revenues of filter suppliers in
the U.S. over the next few years. W. L. Gore has a unique solution to the
mercury problem. The company has developed a medium which can be inserted after
the scrubber. It collects and retains mercury. The medium is not cleanable, but
the amount of mercury in a typical application is only 2-100 lbs/yr. So the
medium will have a life of several years.
For more information on World Fabric Filter and Element Market, click on:
http://home.mcilvainecompany.com/index.php/component/content/article?id=48#n021
Renewable Energy Briefs
Xcel Energy and NCAR Power Up Renewable Energy Forecasts
Xcel Energy announced an expanded agreement with the National Center for
Atmospheric Research for sophisticated renewable energy forecasting. The
agreement with the Boulder, CO-based center extends an existing relationship
that has saved Xcel Energy's 3.4 million electricity customers in eight states
millions of dollars.
In the next two years, NCAR scientists and engineers will develop custom
forecasting systems to enable Xcel Energy control centers in Minneapolis,
Denver, Golden, CO, and Amarillo, TX, to anticipate sudden changes in wind, shut
down turbines ahead of potentially damaging icing events and even predict the
amount of energy generated by private solar panels.
The new project represents the latest venture by NCAR into renewable energy,
which includes a three-year, nationwide project to create 36-hour forecasts of
incoming energy from the sun for solar energy power plants.
The systems will help Xcel Energy provide reliable power to its customers and
reduce costs while moving to greater use of wind and solar. They come at a time
when Xcel Energy is increasing its use of renewable energy in its territories
served by Public Service Co. of Colorado, Northern States Power Co.-Minnesota,
NSP-Wisconsin and Southwestern Public Service Co.
Arise Windpower Reports Record Production in April
Good winds in April resulted in an electricity production of around 51,200 MWh.
Actual output in the same month the previous year was 23,900 MWh.
Since the start of operations the company's wind farms have now delivered more
than 900,000 MWh of green electricity.
Arise Windpower is one of Sweden's leading companies in onshore wind power. Its
business concept is to sell electricity generated at the company's own wind
turbines.
Ormat Technologies Commences Operation of 36 MW Geothermal Power Plant in Kenya
Ormat Technologies, Inc. announced that it reached commercial operation of Plant
2 in the Olkaria III complex in Naivasha, Kenya, increasing the company’s total
generating capacity by 36 MW to 611 MW worldwide. Ormat also plans to add an
additional 16 MW of generation at Olkaria III by building a third plant, which
it expects to complete in 2014. Once Plant 3 is complete, total capacity at the
Olkaria III complex will reach approximately 100 MW. The power generated in the
Olkaria III complex is sold under a 20-year power purchase agreement (PPA) with
Kenya Power and Lighting Company Limited (KPLC).
Ormat financed the new 36 MW plant, as well as the first two phases of the
complex completed in 2000 and 2009, with a $265 million debt facility provided
by the Overseas Private Investment Corporation (OPIC). OPIC will also finance
the construction of Plant 3 with another $45 million debt facility.
Large Scale Solar System Provider Builds Presence in World’s Largest Solar
Market
Solaria Corporation announced it has established operations in China to meet
demand for high efficiency large-scale solar projects.
Solaria have built many large-scale solar power plants in the U.S., Europe and
Asia. Solaria’s current projects in China include several megawatt-size solar
power plants under construction in the Qinghai province and Inner Mongolia. One
project under development is for CECEP Solar Technology Co., Ltd., China's
largest solar power plant investor and operator.
Solaria offers optimized system solutions to provide the best performance and
lowest cost across a wide variety of site location and conditions. Solaria's PV
modules use patented low-cost technology to increase energy yield and provide
reliable performance while matching form and fit of conventional modules. The
modules, optimized for trackers, deliver up to 30 percent more energy than
conventional fixed tilt systems. In order to meet the growing demand for Solaria
modules in China and worldwide, Solaria is also establishing a high-volume
manufacturing facility in China.
Ideal for China, the Solaria STS-AZ is a ground-mounted, single-axis vertical
tracker that enhances PV energy production while reducing design, installation
and operating costs. The STS-AZ tracker’s smart use of materials, ease of
procurement, installation, and engineered reliability makes it a highly robust
and cost-effective choice to maximize the ROI of solar projects.
Solaria Corporation is a solar technology company that designs, manufactures and
integrates solar modules, trackers, and expert design services for large and
utility scale installations.
Kyocera Greens Company Buildings and Saves Energy
As part of its traditional environmental protection and sustainability
activities, Kyocera Corporation plants Green Curtains every spring at its sites
in Japan and select Kyocera Group companies in other parts of the world. Through
the hot summer, curtains of foliage are grown on trellises in front of office
windows and walls at company sites. This not only provides shade but also
shields the buildings from heat radiation — decreasing inside room temperatures
by approximately 3.6 degrees Fahrenheit, which contributes to a reduction of
energy consumption from air conditioner usage.
Furthermore, Green Curtains not only reduce the creation of, but also absorb CO2
emissions: one square meter of foliage absorbs approximately 7.7 lbs of CO2 per
year. In 2012, Green Curtains grown by Kyocera stretched a length of 2,723 ft
and an area of 36,780 ft2 — equivalent to the area of 13 tennis courts — helping
to meet regional energy saving targets in Japan stemming from nuclear power
plant stoppage in the wake of the 2011 earthquake and tsunami.
Since Kyocera first started growing Green Curtains at its Okaya Plant in the
Japanese prefecture of Nagano in 2007, the company has expanded this activity to
28 sites in Japan and affiliates overseas including China, Thailand and Brazil.
This year, Kyocera will also green its headquarters in Kyoto by growing morning
glory vines outside the building and on the third-floor balcony.
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
Headlines for the May 10, 2013 – Utility E-Alert
UTILITY E-ALERT
#1124 – May 10, 2013
Table of Contents
COAL – US
Georgia Power returns Bowen 3 and 4 Coal-fired Units to Service
National Steel City ESP and Fabric Filter Projects
COAL – WORLD
NTPC committed to 1600 MW Gajamara Power Project in Orissa, India
KESC, Sindh Engro team up to build 600 MW Power Plant at Thar Coal Block,
Pakistan
GAS/OIL - US
Ohio Power Siting Board approves 800 MW Oregon Clean Energy Power Plant
873 MW Peaking Eastlake Power Project Cancelled
GAS/OIL – WORLD
Dong Energy drops plans for 1,100 MW Gas-fired Power Plant Project in Germany
299 MW Eye Airfield (UK) Gas-fired Power Plant proposed by Progress Power
E.ON “Seriously Considers” Mothballing Slovak 430 MW Gas-fired Power Plant
Statkraft sheds E.ON Shares, mothballs German Gas-fired Power Plant
Rurelec wins approval for 225 MW Gas Turbine Power Plant in Chile
Gibraltar seeks bids for 80 MW Gas-fired Power Station
NUCLEAR
Kudankulam Nuclear Power Plant gets India Supreme Court nod for Commissioning
Dominion shuts down Kewaunee Power Station Permanently
South Africa to construct New Nuclear Power Plants
Rosatom offers EDF Partnership in Turkey’s First Nuclear Plant (Akkuyu)
BUSINESS
Fuel Tech ULTRA™ Orders in China
Siemens to deliver Three SGT-500 Gas Turbines to Nigeria Cement Company
60 New Siemens Gear Units for Pulverizers in India
Power Plant Operators will spend $122 Billion this Year to build and maintain
Gas Turbines
Top Three Air and Water Monitoring Companies Have 13 Percent Market Share, But
Only Six Percent in Asia
Largest International Air Filter Suppliers are Focusing on Asia
HOT TOPIC HOUR
“Clean Coal Technologies” was the subject of the Hot Topic Hour on May 9, 2013
“Power Plant Automation and Control” plus Electric Power Conference Summary
will be the Subject of the Hot Topic Hour on Thursday May 16, 2013
Upcoming Hot Topic Hours
For more information on the Utility Tracking System, click on:
http://home.mcilvainecompany.com/index.php?option=com_content&view=article&id=72
“Power Plant Cooling Towers and Cooling Water Issues” is the Subject of the Hot
Topic Hour on May 23, 2013. This webinar will be free to all participants.
One of the most important issues facing all types of power plants in the future
is what to do about cooling of condensed steam. Currently, the most common
method for cooling is water withdrawn from a well, river, lake or ocean
following once through a heat exchanger and then discharging the water back into
the source. A typical 500 MW fossil-fueled power plant uses over 12 million
gallons of water per hour for cooling and other process requirements. However,
water is becoming scarcer and power plants are facing new regulations on the
intake and discharge of cooling water.
Water scarcity and intake/discharge regulations will drive those seeking to
construct a new power plant and current plant owners to consider new water
management strategies and alternatives to the “once through approach.” Tighter
air pollution rules may also drive utilities to upgrade cooling water systems to
help reduce SO3 and particulate emissions.
Among the options to consider are improving the efficiency of existing cooling
systems and plant wide conservation and recirculation of wastewater, new
technology such as air-cooled condensers, hybrid air/water cooling systems and
zero liquid discharge systems, the use of reclaimed municipal wastewater for
cooling water systems and co-generation cooling options that use waste steam for
recirculating aquaculture systems, ethanol production and drying sewage sludge.
All of these options offer different benefits as well as challenges depending on
the type and location of the power plant, water requirements, make up or quality
of the water available and applicable local regulations.
The following speakers will address the challenges facing power plant operators
relative to cooling water use and the various options available for cooling
steam with a discussion of the benefits and problems associated with each, the
capital and operating costs of each, economic factors promoting or discouraging
water conservation and regulatory compliance issues affecting power plant water
intake, use and discharge. Current and developing technologies to minimize water
consumption, enhance water quality and increase reuse of water during all phases
of the power generation process will also be addressed.
Brad Buecker, Process Specialist at Kiewit Power Engineers, will present “The
Influence of Tightening Regulations on Cooling Water Treatment.” Once-through
cooling is no longer a consideration for new and planned power plants, primarily
due to pending 316a and 316b regulations. Rather, we almost exclusively see
cooling towers or air-cooled condensers as the choice for steam condensation at
combined cycle plants. However, tightening regulations on the quality, and
sometimes quantity, of power plant wastewater streams are influencing cooling
tower treatment programs. This presentation examines several of the most
prominent trends in the cooling water treatment industry.
Brett DeRousse, National Account Manager for Hydrolox, will present “Potential
impacts of 316(B) regulatory controls and their affects on existing power plant
cooling water intakes.” Nearly half of the US utility-owned electric generating
capacity is cooled by once-through cooling systems. These power plants withdraw
cooling water primarily from surface water bodies. Section 316(b) of the Clean
Water Act requires that the location, design, construction and capacity of
cooling water intake structures reflect the best technology available (BTA) for
minimizing adverse environmental impacts. The selected BTA is likely to be
Modified Traveling Water Screens (TWS) for many of the affected power plants. Of
large concern to these power plants is not only the compliance with 316(b) but
the overall financial affect it will have on the power plants O&M. The new rule
will require power plants to continuously operate Traveling Water Screens (TWS),
whereas they are typically run off of pressure differential or on timers. The
overall affect on the power plants O&M budget could be significant. Over the
past several years, several different types of modified TWS technology have been
developed, specifically for improving fish mortality rates. This presentation
will provide a brief history of the development of modified screens and fish
return systems, as well as a technical overview of several different modified
TWS technologies, and review applications where those technologies are most
applicable. Finally, he will discuss the compliance alternatives and their long
term financial affects on power plants.
Daniel M. Cicero, Senior Industry Development Manager Power Group, Water &
Process Services Division of Nalco Company, will discuss how power plants can
reduce their environmental impact by using good water chemistry. Every power
plant wants to be a good corporate citizen of the community in which it resides.
Every power plant wants to minimize its environmental impact. Those desires must
be balanced with the needs of the community for low-cost power. This
presentation will discuss three cases where power plants achieved that balance.
In one case, using water chemistry modeling allowed a power plant to reduce
withdrawals from a stressed waterway. In another, changing water chemistry
reduced the impact of the power plant on the local community. In a third, the
ability to respond to changing water quality reduced water costs and demands on
the local water supply.
Trent T. Gathright, Sales & Marketing Manager Cooling Water Products at Ovivo
USA, LLC Energy Group – Americas, will briefly address different type water
intake screens and 316(b) alternatives. Numerous factors affect power plant
cooling water at both once-through and closed cycle types. Various methods have
been developed to deal with debris at both type power plants including
indigenous debris, foreign blown in material and element disintegration. Pending
316(b) may also affect how make-up water intakes are handled.
Andrew Howell, Senior System Chemist for Xcel Energy, will discuss several
technologies that are available for condensing steam in power plants. Increasing
difficulty with obtaining adequate cooling water supply for new generating units
has required some power plant designs to use dry or hybrid (wet + dry) cooling
systems. While necessary in some cases, these options have significant downsides
that must be considered in planning for construction and operation.
This webinar will be free to all participants. To register for the Hot Topic
Hour on “Power Plant Cooling Towers and Cooling Water Issues” May 23, 2013 at
10:00 a.m. (DST), click on:
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 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
May 23 Power Plant Cooling Towers and Cooling Water Issues FREE Power
May 30 Air Pollution Control Markets (geographic trends, regulatory
developments, competition, technology developments) Market Intelligence
June 6 Report from Power-Gen Europe (update on regulations, speaker and
exhibitor highlights) Power
June 13 Monitoring and Optimizing Fuel Feed, Metering and Combustion in Boilers
Power
June 20 Dry Sorbent Injection and Material Handling for APC Power
June 27 Power Generation Forecast for Nuclear, Fossil and Renewables Market
Intelligence
July 11 New Developments in Power Plant Air Pollution Control Power
July 18 Measurement and Control of HCl Power
July 25 GHG Compliance Strategies, Reduction Technologies and Measurement Power
August 1 Update on Coal Ash and CCP Issues and Standards Power
August 8 Improving Power Plant Efficiency and Power Generation Power
August 15 Control and Treatment Technology for FGD Wastewater Power
August 22 Status of Carbon Capture and Storage Programs and Technology Power
August 29 Pumps for Power Plant Cooling Water and Water Treatment Applications
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
To register for the “Hot Topic Hour’, click on:
http://www.mcilvainecompany.com/brochures/hot_topic_hour_registration.htm.
----------
You can register for our free McIlvaine Newsletters at:
http://www.mcilvainecompany.com/brochures/Free_Newsletter_Registration_Form.htm.
Bob McIlvaine
President
847-784-0012 ext 112
rmcilvaine@mcilvainecompany.com
www.mcilvainecompany.com
191 Waukegan Road Suite 208 | Northfield | IL 60093
Ph: 847-784-0012 | Fax: 847-784-0061
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