Join the Coal-fired Power Linkedin Groups Created by McIlvaine
McIlvaine has initiated a number of linkedin groups to compliment the Alerts
newsletters, webinars and databases included in PPAQD Decisions (all water,
energy and air issues in coal-fired power plants).
If you subscribe to PPAQD, you can contribute information to the intelligence
system and participate in the webinars. PPAQD is free of charge to power plants
around the world so it is a great way to communicate with them. The
details on subscribing are found at:
44I Power Plant Air Quality Decisions (expanded
to PPAQD Decisions (all water, energy and air issues in coal-fired power plants)
LINKEDIN DISCUSSION GROUPS
Linkedin
Power Plant Ultrapure Water
Analysis of hardware and treatment options to create ultrapure water for steam
generation and then to purify and move the recycled condensate. Options for
filtration, ion removal, valves, pumps, instruments and chemicals are included.
How is the best way to remove natural organic
matter?
Robert McIlvaine Ovivo provide their
answer in a McIlvaine webinar which is recorded and available in PPAQD.
Each process step has specific reduction rates for each NOM family:
- TOC concentrations in raw water is not sufficient for an optimum design high
safety factor
- Detailed fractionation of TOC in major groups allow a precise design (if
specific removal rates for each process are known)
- 80% removal can only be anticipated using conventional IX based systems
- 90-95% removal usual using RO based systems (single or twin pass RO).
What are the best condensate polishing choices?
McIlvaine has been reporting on various condensate polishing options at BHE
plants. The need to upgrade to Pall filters from the less efficient Cuno filters
was in part due to ACC contamination of the condensate. What other coal-fired
power plants are using ACC?
Robert McIlvaine Ovivo has a very large
condensate removal system at a South African coal-fired power plant which also
uses ACC for cooling. Let’s find out how this installation is performing.
Robert McIlvaine Here is the summary of
a PEI article on the Eskom plant with Ovivo condensate polishing. You will find
the complete text in PPAQD. The Eskom Medupi power plant has installed an Ovivo
Condensate Polishing Plant (CPP) at all six coal-fired units. The CPP is
designed to produce treated condensate with cation conductivity less than 0.1
μS/cm, chloride less than 1 μg/l (less than 1 ppb) and silica less than 5 μg/l
(less than 5 ppb). The CPP treats 100 per cent of the condensate flow under
normal operating conditions. This removes iron and copper corrosion products, as
well as dissolved cationic and anionic impurities, while allowing ammonia ions
to pass through, when operated in the ammonia cycle, maintaining a high pH to
protect the condenser. The first stage of condensate polishing utilizes
cartridge filters to remove most of the particulates.
Service vessels containing ion exchange resins are used to remove impurities
before the water is fed back into the boiler.
Robert McIlvaine More on Eskom: Eskom
chose a system with separate vessels for cation and anion resins to give maximum
flexibility of operation.
The resins remove contamination in the condensate by exchanging dissolved
impurities for hydrogen and hydroxide ions, as the water passes through the
service vessels. The resin also acts as a filter to remove any remaining
particles.
By utilizing separate vessels for resin, the anion vessel can be bypassed at
those times when condensate temperatures rise higher than those recommended by
the anion resin manufacturer. Failure to place the anion vessel offline during
short periods when temperatures spike can shorten the longevity of the resin.
As the resin becomes exhausted, it slowly loses its capacity to exchange ions
which reduces its ability to exchange contaminants. Eventually, it reaches the
point when the quality of the water deteriorates. Technicians can detect such an
occurrence by measuring water quality parameters such as cation conductivity.
Linkedin NOx Scrubbing Group
This group consists of NOx generators, McIlvaine
subscribers and selected experts or contributors. It covers coal-fired power,
incineration, chemical, refining and other industries generating NOx.
Should coal-fired boiler scrubbers remove NOx?
SCR and SNCR are proven methods for NOx removal but their situations
where a relatively small amount of NOx needs to be removed and there
are existing scrubbers. Ozone can be used for oxidizing NOx to NO2
and then N205. Refineries are using ozone ahead of scrubbers. Why shouldn't the
power industry consider it? Utilities in Utah, Alabama and Mississippi have
suddenly been required to remove more NOx. A detailed analysis of
this option is being pursued on a special website set up for BHE. Insights from
this linked-in group will be conveyed to the BHE subscribers. One major
question is whether to use peroxide instead of just ozone ahead of the
scrubbers?
Robert McIlvaine Refineries are using
ozone instead of SCR. There is the assumption that Ozone scrubbing is too
expensive. If so, why are refineries using it. Is it a question of the quantity
of NOx to be removed? If so, then those power plants which only
need to remove another 0.06 lbs./MMBtu are more likely candidates than those who
need to remove 0.2 lbs./MMBtu or more.
Where is NO2 being absorbed in plate
or packed towers?
Robert McIlvaine Conversion of NO to NO2
- (Envitec) One tray is used in the case there is a sufficiently high
concentration of NO in the inlet gas stream or sufficiently low outlet
concentration limit for NO. NO is essentially insoluble in water, but it
can be quickly oxidized to NO2 by chlorine dioxide (ClO2) or ozone
(O3). This can be done using a packed bed, but the reaction of NO occurs in the
gas phase. The packed bed functions as a ClO2 generator and static mixer, or as
a static mixer for ozone injected in the form of an aqueous solution. ClO2 can
be generated by the reaction of sodium chlorite (NaClO2) with a strong acid.
Sulfuric acid (H2SO4) is commonly used, but if the air being scrubbed contains
enough nitric acid fumes, it may not be necessary to add much H2SO4. Most
NOx scrubbers don't have an oxidation stage. When NOx
is generated by the reaction of nitric acid with metals, it usually consists
mainly of NO2. NO is invisible, and it is much less toxic than NO2.
Robert McIlvaine The Mt. Vernon, IN
plant of GE Plastics has installed a NOx scrubber. When such GE
Plastics products as Ultem resins are produced, nitric acid is used, and
emissions from this step are tightly controlled. But to address upset
conditions, the company opted to install an emergency scrubber that can treat
up to 66,000 ft3/min of air containing 9,600 ppm nitric acid vapor and 1,100 ppm
of NO2 for 1 h.To
meet this need, Tri-Mer Corp. has successfully adapted the design of its
continuous-duty NOx. The Tri-Mer system used at Mt. Vernon
comprises two horizontal scrubbing stages, with each stage having its own
circulation system. A proprietary combination of caustic, sodium hypochlorite
and a reducing agent is used.
Robert McIlvaine The Kanto Denka process
(1) employs a scrubbing solution containing 0.2% hydrogen peroxide and 10%
nitric acid while the Nikon process uses a 10% sodium hydroxide solution
containing 3.5% hydrogen peroxide. A fourth process, the Ozawa process, scrubs
NOx by spraying a hydrogen peroxide solution into the exhaust gas
stream. The liquid is then separated from the gas stream and the nitric acid
formed is neutralized with potassium hydroxide. The excess potassium nitrate is
crystallized out, and the solution reused after recharging with hydrogen.
Member coordination between component and system suppliers
Belco and Xylem are participating. Let’s discuss potential beyond refineries to
other applications but also ozone in conjunction with other technologies.
Comments on both subjects?
Robert McIlvaine Belco LOTOX: Marathon
conducted a review of several options to reduce nitrogen oxides (NOx)
from its 52,000 barrels per day FCCU. The LOTOX technology was identified as a
potential NOx control technology. Unfortunately, the LOTOX
technology had never been used on an FCCU. Marathon needed more assurance that
applying it to an FCCU would result in similar performance to that experienced
in the other application. To that end, Marathon, BOC and Belco conducted a
demonstration of Belco’s EDV wet scrubbing system with LOTOX technology. The
demonstration was conducted October through November 2002. Following review of
the results, Belco finalised its proposal to Marathon for the system and
eventually concluded negotiations for the design and supply of the system for
the Texas City refinery. This commercial system successfully started operating
in February 2007, achieving all established goals and confirming the results of
the demonstration.
Linkedin Flue Gas Desulfurization (FGD) Group
Power plants generate SO2 which can be captured and converted to
disposable products or usable byproducts such as gypsum, sulfuric acid, or
ammonium sulfate fertilizer. The choice for an individual plant is affected by
many factors. There are 1000s of components in these systems. the corrosive and
abrasive environment dictates careful selection of components as well as special
operation and maintenance practices. Discussions of all of this are encouraged.
Robert McIlvaine Ozone injection creates
NO2 and N205. the N205 is more readily absorbed in the scrubber. NO2
is also absorbed but at lower efficiency rates. Shiaw Tseng of Graymont believes
that there are concerns about some the reactions which can take place. We are
asking Shiaw to elaborate on this.
Filter media for FGD belts, drums and filter
presses
Filter belts are used for gypsum washing, filter presses are used for FGD
wastewater. Which filter media work best on these applications?
Robert McIlvaine One of the experts on
this subject is Robbie Waters of Menardi Filtex. His contact info is in the OEM
networking directory. For those of you with access to BHE connect, his full
profile appears in the BHE Supplier Connect Directory. You can also find him on
Linkedin under Robert Waters, Nederman.
Level and pressure measurement requirements in
FGD system
A number of solids, liquids and gases are involved in flue gas desulfurization
(FGD). What are the best selections for level and pressure measurement for each
unique application?
Robert McIlvaine Vega has a page devoted
to FGD on its website. It includes pressure measurement in the FGD absorber
pump, level measurement in the absorber sump and also the adipic acid holding
tank. Adipic acid is used to improve SO2 capture. A number of other
reagents are now being considered for purposes such as prevention of mercury
remissions or for separation of the mercury from the gypsum.
Dry FGD systems require level control in the lime storage bins. The pressure
measurement in lime slurry injection in spray drier FGD is critical. How do Vega
instruments differ from others and what are the advantages in the corrosive and
abrasive environments encountered?
Linkedin Coal-fired Power Plant Instrumentation and Controls Group
Coal-fired power plant instrumentation and controls
The smart technology developments along with software to optimize the processes
offers very high ROi for coal-fired power plant operators. The insights provided
by this discussion group will be reflected in the McIlvaine PPAQD Decisions
program with six newsletters and thousands of pages of analysis on coal-fired
power plant technology. Since this group is limited to power plants and
subscribers with access to PPAQD, the discussion group will use PPAQD as a
foundation of discussions.
Two approaches include investment in instruments inside the furnace to measure
O2 and CO at many locations and then to adjust burners. The other approach is
based on results. The system learns from various damper settings and the
resultant impact on operations and adjusts each setting until the optimum
results are obtained. Siemens has acquired TDL technology and is advancing the
measurement approach. GE has acquired Neuco and is promoting the learning and
neural network approach. What are the advantages of each?
What is the advantage of radar based level
control in coal-fired power plants?
In 2014, a new radar sensor for continuous measurement of bulk solids, VEGAPULS
69, was introduced. Is this being successfully applied in coal-fired power
plants? Are other radar based level control companies also finding success in
this application? With the expanded use of direct sorbent injection (DSI) there
are new level control challenges.
New Approach allows Subscribers to Reach the Summit of the Mountain of
Information on Gas Turbine and Reciprocating Engine Technology
The available information on combustion, flow control, treatment and
environmental compliance for gas turbines and reciprocating engines is doubling
every few years. It is now more challenging than climbing Mt. Everest to
find the most current and relevant information. Rapid developments include
zero liquid discharge (ZLD) technologies, repairable valves, high efficiency air
inlet filters, treatment of feedwater for HRSGs and emission control
improvements. The need for constant cycling of turbine generators to compensate
for wind and solar fluctuations is creating some unanticipated problems.
Purifying the CO2 exhaust for adjacent use in indoor agriculture is a
big opportunity but also a challenge.
The four knowledge needs are Alerts, Answers, Analysis and Advancement.
These needs are served in a number of unique ways in the McIlvaine’s Gas
Turbine, Reciprocating Engines Decisions. The system is free of
charge to any power plant in the world. This wide reach makes it very
important to suppliers who add considerable value with their input.
Alerts:
The service includes a biweekly Alert.
Answers:
The intelligence system includes thousands of pages of papers, articles and
power point presentations. The coverage is international. Many
developments in one country are not known in other countries. A system
used by power plant owners and suppliers in all countries assures better
information exchange.
Analysis:
There are regularly scheduled webinars. Hundreds of hours of recorded
webinars can be immediately retrieved. A number of LinkedIn discussion
groups have been created. The group entitled “HRSG Valve Decisions” addresses
the challenge of frequent cycling and the advantages of repairable valves. The
webinars provide ways to aggregate and analyze the data being added in the
LinkedIn discussion groups. The air inlet webinars have provided answers
to the question as to when high efficiency inlet air filters should be selected.
The intelligence system provides the foundation for discussion group
participants.
One of the primary goals is to make it easier for power plants to make total
cost of ownership analyses at reasonable cost. The system includes white
papers and identifies experts who can make contributions.
Advancement:
The recorded webinars and the intelligence system are very valuable as training
tools. They can be utilized for basic training or keeping the most senior people
current with new developments.
For more information, click on:
59D Gas
Turbine and Reciprocating Engine Decisions.
New Approach allows Subscribers to Reach the Summit of the Mountain of
Information on Coal-fired Boilers
The available information on combustion, flow control, treatment and
environmental compliance for coal-fired power plants is doubling every few
years. Finding the most current and relevant information is now more
challenging than climbing Mt. Everest.
The four knowledge needs are Alerts, Answers, Analysis, and Advancement.
These needs are served in a number of unique ways in McIlvaine’s PPAQD
Coal-fired Power Plant Decisions. The system is free of charge to
any power plant in the world. This wide reach makes it very important to
suppliers who add considerable value with their input.
Alerts:
The service includes six alerts and newsletters.
Answers:
The intelligence system includes thousands of pages of papers, articles and
power point presentations. The coverage is international. Many
developments in one country are not known in other countries. A system
used by power plant owners and suppliers in all countries assures better
information exchange.
Analysis:
There are regularly scheduled webinars. Hundreds of hours of recorded
webinars can be immediately retrieved. A number of LinkedIn discussion
groups have been created. They include individual air pollution control
technologies such as fabric filtration and dry scrubbing. There are
separate groups covering each component e.g. valve, instrumentation and groups
organized around processes such as coal combustion residues and wastewater
treatment.
The webinars provide ways to aggregate and analyze the data being added in the
LinkedIn discussion groups. The intelligence system provides the
foundation for discussion group participants.
One of the primary goals is to make it easier for power plants to make total
cost of ownership analyses at reasonable cost. The system includes white
papers and identifies experts who can make contributions.
Advancement:
The recorded webinars and the intelligence system are very valuable as training
tools. They can be utilized for basic training or keeping the most senior people
current with new developments.
For more information, click on:
44I Power
Plant Air Quality Decisions (Power
Plant Decisions Orchard)
Utility E-Alert Tracks Billions of Dollars of New Coal-fired Power Plants on a
Weekly Basis
Here are some Headlines from the Utility E-Alert
UTILITY E-ALERT
#1296 – October 28, 2016
Table of Contents
COAL – US
COAL – WORLD
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.
Upcoming Hot Topic Hours
DATE |
HOT TOPIC HOUR
AND DECISION
GUIDE SCHEDULE
The opportunity
to interact on
important issues |
TBA
Markets |
Food
- Analysis
of 12 separate
applications within food and
beverage with analysis of valve,
pump, compressor, filter,
analyzer and chemical options;
impact of new technologies such
as forward osmosis. |
TBA
Markets |
Municipal Wastewater
-
Quality of pumps, valves,
filters, and analyzers in
Chinese and Asian plants; new
pollutant challenges; water
purification for reuse. |
TBA
Markets |
Mobile Emissions
-Reduction
in CO, VOCs, and particulate in
fuels, oils, and air used in on
and off road vehicles; impact
of RDE and failure of NOx
traps and the crisis in Europe
created by the focus on clean
diesel. |
Click here to Register for the Webinars
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You can register for our free McIlvaine Newsletters at:
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Bob McIlvaine
President
847-784-0012 ext. 112
rmcilvaine@mcilvainecompany.com
www.mcilvainecompany.com