Lots of New Challenges for Power Plant Chemicals Was the Hot Topic on
September 25
The level of knowledge demonstrated by the speakers relative to the challenges
of preventing corrosion and malfunction of gas turbine combined cycle power
plants which are cycling hundreds of times per year and may be using poor
quality source water, makes a persuasive case for continuing expert advice.
Chemicals are a big expense. Failure to maintain the right chemistry is even
more expensive. The average combined cycle power plant does not have the
staffing of a large nuclear plant. So it pays to contract with experts who can
monitor the chemistry programs.
The recorded webinar yesterday is available to you as a Utility E-Alert
subscriber. It is also available free of charge as part of two free systems for
power plants around the world. One knowledge system deals with all the gas
turbine issues and another with all the coal issues. Power plants are encouraged
to use the systems for decision making but also to use the websites and
recordings for training programs. The session yesterday will be valuable for
both purposes.
Overview of Power Plant Chemicals
Bob McIlvaine reviewed some of the challenges:
Use of municipal treated wastewater (Chemtreat article posted)
Rapid cycling (reviewed in monitoring session earlier)
Air Cooled Condenser and iron transport (reviewed in monitoring recording)
Steam Generator - Continuous Analyses
Effluent standards (CCR and Effluent - Continuous Analyses)
Zero liquid discharge
MIOX Summary - Tom Muilenberg
The Mixed oxidant system is providing savings in terms of cooling tower chemical
usage and power plant output.
Ψ The NIPSCO power plant achieved cleaner condensers, saving ~$640,000/yr.
Ψ Proprietary biocides could not control biofilm in 90,000 ton tower. Visible
biofilm buildup in the condenser.
Ψ Mixed oxidant chemistry eradicated the biofilm. Replaced the biocide regime.
Ψ Paul Schrock, NIPSCO Senior Chemist stated, "Reducing our treatment
regimen.down to a single mixed oxidant product generated on site has resulted in
substantial treatment chemical and labor cost savings."
HDR Summary - Colleen Layman
Colleen Layman advised that chemistry limits developed for traditional
industrial watertube boilers are not generally applicable to HRSGs.
Chemistry is unique due to:
o Multiple pressure circuits in one casing
o Complex flow patterns
o Rapid cycling or fast start needs
o Integration of cycles
o Multitude of design options
Selection of operating chemistry
o Program needs to factor in unit specific design and operational aspects
Cycling and Fast Start Considerations
Cycling service long associated with phosphate hideout problems
Recommend considering AVT programs for cycling service + polishers
Where aux boilers are used for holding vacuum, warming, etc.
o Treatment program should match main cycle
Fast start designs gaining in popularity
o OEM chemistry requirements may be quite different than standard fare
o No tolerance for old school chemistry holds
o High purity system maintenance a priority
Challenges with ACCs
Difficulties in cleaning
Large surface area promotes iron transport particularly during restarts & load
changes
Air in-leakage potential
Prone to FAC
Consider installing permanent condensate polishers
o Precoat vs. Deep Bed
Supplemental HP feedwater pH adjustment
Use of amine blends with different vapor/liquid distribution ratios
Kiewit Summary - Brad Buecker
Brad answered some of the most important questions facing the industry.
"Bob McIlvaine and his staff posed a set of questions to me that are very
important regarding HRSG water/steam chemistry and prevention of corrosion and
fouling in steam generators. Even seemingly minor issues have been known to
cause failures that cost power producers millions of dollars and in some cases
even claimed lives. This is the ultimate cost. Each question and a straight
forward answer follows:
Question #1
Are chemical treatment methods available to reduce flow-accelerated corrosion
(FAC) in HRSGs?
Answer #1
Yes. For starters unless the feedwater system contains copper alloys
(virtually non-existent in HRSGs) do not use an oxygen scavenger/reducing agent.
Second, keeping the pH elevated in a mid 9 range or even a bit higher,
particularly in the LP circuit, will help with single-phase FAC.
The situation is more complicated for two-phase FAC.
Please feel free to contact me directly for a more detailed discussion of FAC.
(brad.buecker@kiewit.com)
Question #2
With fast start HRSGs and constant cycling, what chemical additions will
counter some of the negative consequences of this operating mode?
Answer #2
I have worked with my friend Dan Dixon of Lincoln Electric System on this
issue, and we co-authored an article for Power Engineering on the subject.
Keep oxygen out of the system during shutdowns. The best method is nitrogen
blanketing. Nitrogen generators are available that can do a great job in
producing 99.9-plus percent N2.
Remove oxygen from makeup water. Membrane systems are available that can
reduce water saturated with oxygen to low ppb levels.
Question #3
If the plant has an ACC rather than a water-cooled condenser and the
condensate iron content is much higher, how can this problem be solved?
Answer #3
Install a full-flow particulate filter in the condensate line. Most of the
iron generated from corrosion in ACCs is particulate in nature.
I purchased one of these units at a coal-fired plant where I worked to remove
iron particulates following boiler chemical cleanings. The equipment paid for
itself several times over after the first use.
The original system had filters with 7-micron pore size, but plant personnel
found that 10-micron worked just as well.
Question #4
What are the water chemistry issues facing GTCC operators that are unique to
this type of power generation?
Answer #4
Several major issues are facing plant operators, some of which transcend many
industries.
Dealing with less-than-pristine raw water sources. Municipal wastewater
treatment plant effluent is one example.
Discarding the idea that an oxygen scavenger/reducing agent is needed for
condensate/feedwater treatment.
Handling the different chemistry regimes in multi-pressure HRSGs.
New requirements for cooling tower chemical treatment.
Dealing with increasingly stringent wastewater discharge guidelines.
Question #5
What are the chemical treatment needs if zero liquid discharge (ZLD)
technology is mandated?
Answer #5
ZLD is a complex subject, not to be taken lightly.
One method gaining popularity is treatment of the discharge with membrane
technologies to greatly reduce the volume. Even so, a waste stream still
remains. Methods, all of which can be problematic, to deal with the final waste
stream include:
Evaporation ponds
Deep-well disposal
Truck the liquid off-site.
Thermal evaporation/crystallization with solids disposed in an approved
landfill
Question #6
Treated wastewater often contains much higher concentrations of ammonia,
phosphorus, organics, and suspended solids than fresh water. These impurities
can cause induce excessive microbiological fouling in cooling systems, can carry
over into the wastewater stream, and can be problematic for makeup water
systems.
Answer #6
Treated wastewater often contains much higher concentrations of ammonia,
phosphorus, organics, and suspended solids than fresh water. These impurities
can cause induce excessive microbiological fouling in cooling systems, can carry
over into the wastewater stream, and can be problematic for makeup water
systems.
Makeup water clarification and solids precipitation may be a requirement to
treat these streams.
Selection of an alternative to chlorine (bleach) such as chlorine dioxide may
be necessary.
Cooling tower sidestream filtration is never really a bad idea.
Question #7
How can plugging of combustion turbine inlet air fogging nozzles be prevented,
and what is necessary to prevent introduction of contaminants to a combustion
turbine?
Answer #7
Any water injected ahead of or into a combustion turbine for cooling, NOx
control, or power augmentation must be very high-purity, i.e., a stream from the
makeup water system. Impurities can be very harmful to combustion turbine blades
and rotors in the extremely harsh environment. Far more often than fogging
systems I see evaporative coolers used for inlet cooling. I also have assisted a
group that developed an ammonia-based chilling system for inlet air cooling (and
heating in the winter). It eliminates the issue of poor water possibly being
inducted into the turbine.
You can view and listen to the recording at Power Plant Water Treatment
Chemicals 100 minutes.
You will need to enter your name and email address after clicking link to view
recording.
Presentations follow:
Power Plant Chemicals Webinar - Hot Topic Hour September 25, 2014
The level of knowledge demonstrated by the speakers relative to the challenges
of preventing corrosion and malfunction of gas turbine combined cycle plants
which are cycling hundreds of times per year and may be using poor quality
source water makes a persuasive case for continuing expert advice.
Revision Date: 9/25/2014
Tags: 221112 - Fossil Fuel ????, 221112 - Fossil Fuel ????, McIlvaine, Kiewit,
Miox, HDR Engineering, Chemical, Cooling Tower, Sodium Hypochlorite, Hydrogen
Peroxide, Consulting
________________________________________
Cooling Towers by Tom Muilenberg, Miox - Hot Topic Hour September 25, 2014
The Mixed oxidant system is providing savings in terms of cooling tower chemical
usage and power plant output.
Revision Date: 9/25/2014
Tags: 221112 - Fossil Fuel ????, 221112 - Fossil Fuel ????, Miox, Chemical,
Cooling Tower, Sodium Hypochlorite, Hydrogen Peroxide
________________________________________
Water Treatment Chemicals for Gas Turbine Combined Cycle Power Plants by Colleen
Layman - Hot Topic Hour September 25, 2014
Colleen Layman advised that chemistry limits developed for traditional
industrial watertube boilers are not generally applicable to HRSGs. Chemistry is
unique.
Revision Date: 9/25/2014
Tags: 221112 - Fossil Fuel ????, 221112 - Fossil Fuel ????, HDR Engineering,
Chemical, Consulting
________________________________________
Water Treatment and Chemistry Answers for HRSG Operators by Brad Buecker, Kiewit
- Hot Topic Hour September 25, 2014
Questions answered regarding HRSG water/steam chemistry and prevention of
corrosion and fouling in steam generators. Even seemingly minor issues have been
known to cause failures that cost power producers millions of dollars and in
some cases even claimed lives. This is the ultimate cost.
Revision Date: 9/25/2014
Tags: 221112 - Fossil Fuel ????, 221112 - Fossil Fuel ????, Kiewit, Chemical,
Consulting
________________________________________
Power Plant Chemicals Overview by Bob McIlvaine - Hot Topic Hour September 25,
2014
Bob McIlvaine reviewed some of the challenges.
Use of municipal treated wastewater (Chemtreat article posted)
Rapid cycling (reviewed in monitoring session earlier)
Air Cooled Condenser and iron transport (reviewed in monitoring recording)
Steam Generator - Continuous Analyses
Effluent standards (CCR and Effluent - Continuous Analyses
Zero liquid discharge
Revision Date: 9/25/2014
Tags: 221112 - Fossil Fuel, 221112 - Fossil Fuel, McIlvaine, Chemical,
Consulting
OIL & GAS SALES LEADS HEADLINES
September 19, 2014
Oil and Gas Project Tracking is available at a discount to Water & Wastewater
Treatment Chemicals World Market subscribers.
Treatment chemicals are an important addition to most oil and gas processes.
Access to details on the worldwide oil and gas projects is provided at a
substantial discount to Water & Wastewater Treatment Chemicals World Market
subscribers.
(Listed by most current date)
SOCAR Lets Contract to Hamon Thermal Europe for Baku Refinery (Article Dated:
9/19/2014)
Construction Begins on PDVSAs Puerto La Cruz Refinery Revamp (Article Dated:
9/19/2014)
SOCAR Builds Gas-cleaning Plant at Baku Refinery (Article Dated: 9/19/2014)
CB&I Awarded Contracts for Hydrocracker Complex in Russia (Article Dated:
9/18/2014)
Enterprise Products Begins Exporting Refined Products from Beaumont Marine
Terminal (Article Dated: 9/18/2014)
KBR Wins PMC Contract for Major Revamp Program at Omsk Refinery (Article Dated:
9/18/2014)
Monroe Energy, Bridger Agreement to Supply 65,000 Barrels of Crude Daily to
Trainer Refinery (Article Dated: 9/18/2014)
Wison Commences Puerto La Cruz Refinery Deep Conversion Site Preparation Project
in Venezuela (Article Dated: 9/18/2014)
Commercial Production Begins at Chevrons New Premium Base Oil Plant (Article
Dated: 9/18/2014)
Jacobs Receives Project Services Contract from BP (Article Dated: 9/18/2014)
ExxonMobil Announces Antwerp Refinery Investment of More than $1 Bln (Article
Dated: 9/18/2014)
Bakken Energy Subsidiary Nations Oil and Gas Signs LOI to Acquire Utahs Green
River Refinery (Article Dated: 9/17/2014)
Pemex Lets JV Contracts for Two Refineries (Article Dated: 9/17/2014)
Mistral Starts Construction of $70 Mln Saskatchewan NGL Plant, Pipeline (Article
Dated: 9/15/2014)
KMP Expanding Kinder Morgan Crude and Condensate System (Article Dated:
9/15/2014)
The Patriot Energy Center Holds Groundbreaking of 829 MW Marcellus Shale-Gas
Power Plant (Article Dated: 9/12/2014)
Metso's Flow Control Technology Selected for Petronas Gas Processing Plant
Modernization Project (Article Dated: 9/12/2014)
Pioneer Natural Resources Announces $495 Mln Sale of Hugoton and Barnett Shale
Assets (Article Dated: 9/12/2014)
Large-Scale Contamination Removal by OriginOil's Frack Water CleanupTechnology
Verified by Independent Lab (Article Dated: 9/12/2014)
GE Energy Financial Services and Casillas Petroleum Partner to Acquire Kansas
Oil & Gas Reserves (Article Dated: 9/12/2014)
Swift Energy Announces 24Percent Increase in Second Quarter 2014 Production
(Article Dated: 9/11/2014)
High Plains Gas Prepares to Resume Gas Production (Article Dated: 9/11/2014)
Horizon Energys East Texas Project Generates Revenues (Article Dated:
9/11/2014)
ONEOK Partners to Invest $605 to $785 Mln in New Demicks Lake, ND Natural Gas
Processing Facility (Article Dated: 9/11/2014)
Weir Group Acquires Wellhead Supplier, Metra Equipment (Article Dated:
9/11/2014)
Husky Starts Work on Second Liwan Field Platform Offshore China (Article Dated:
9/10/2014)
Nigeria Deploys GEs Mobile Gas Turbines at Its NNPC Port Harcourt Oil Refinery
(Article Dated: 9/10/2014)
McDermott Awarded Megalodon Platform Installation in Gulf Of Mexico (Article
Dated: 9/10/2014)
Halliburton Announces Joint Venture with SPT Energy Group (Article Dated:
9/9/2014)
Whiting Petroleum Acquires Kodiak Oil & Gas Corp in All-Stock Transaction Valued
at $6 Bln (Article Dated: 9/9/2014)
Weatherford to Sell to Rosneft Russian and Venezuelan Land Rig Operations for
$500 Mln (Article Dated: 9/9/2014)
AMEC Awarded Premier Oil Contract Offshore Falklands (Article Dated: 9/9/2014)
Egypts Ganoub El-Wadi Proposes International Tender for Oil and Gas Exploration
(Article Dated: 9/9/2014)
Wood Mackenzie Sets the Record Straight on U.S. Crude Oil Exports (Article
Dated: 9/9/2014)
EIA Conference Speakers Warn of US Light Crude Oils Day of Reckoning (Article
Dated: 9/9/2014)
Iran to Start Up Phases 15 and 16 for South Pars Third Gas Plant (Article Dated:
9/9/2014)
Link Strengthened Between Wastewater Injection and Oklahoma Earthquakes (Article
Dated: 9/9/2014)
Swift Energy and PT Saka Energi Indonesia Close Joint Venture to Develop Fasken
Eagle Ford Acreage (Article Dated: 9/8/2014)
Phillips 66 Board Approves Increased 2014 Capital Program and Additional Share
Repurchases (Article Dated: 9/8/2014)
Technip and Wijaya Karya Consortium Secures Onshore Contract for Matindok Gas
Development Project (Article Dated: 9/8/2014)
OriginOil Announces Breakthrough Chlorine Dioxide Pre-Treatment for its
CLEAN-FRAC System (Article Dated: 9/8/2014)
NRG Energy and JX Nippon to Build Largest Post-Combustion Carbon
Capture-Enhanced Oil Recovery Project (Article Dated: 9/8/2014)
For more information on Oil, Gas, Shale and Refining Markets and Projects click
on: http://home.mcilvainecompany.com/index.php/markets/28-energy/471-n049
WORLD MUNICIPAL WASTEWATER PROJECT MONTHLY NEWS HEADLINES
September 2014
This monthly update is devoted to wastewater infrastructure news around the
world, outside of the United States and Canada, and is meant to complement
McIlvaine's Water & Wastewater Treatment Chemicals: World Market.
ASIA
Australia: Wastewater Recycling Plant Planned for Mixed Use Development in
Sydney
China: Sludge Treatment Project in Beijing to Generate Biogas and Biosolid
Products
China: Government Appoints Canadian Company to Take Lead Role in Building
WWTPs
China: Sound Global Announces Expansion Projects and New O&M Contract
India: Delhis Sewerage Master Plan for 2031 Proposes 75 New WWTPs
Vietnam: US$11.5 Million WWTP in Ancient Town of Hội An is Approved
EUROPE
UK: New £200 Million WWTP in Liverpool On-Track for Completion Next Spring
UK: Southern Water Awards Costain and Galliford Try Major AMP6 Projects
MIDDLE EAST
Bahrain: Xylem Awarded US$7.3 Million Contract for Tubli WWTP Expansion
Jordan: Germany Offers 80 Million for Water Projects to Offset Burden of
Hosting Syrian Refugees
UAE: Abu Dhabi Plans 100 Percent Wastewater Reuse by 2030
NORTH AND SOUTH AMERICA
Brazil: South Korean Firm Awarded US$767 Million Contract for Three WWTP
Projects
Brazil: New Sanitation Project Announced to Clean up Sailing Venue by 2016
Olympics
Colombia: Government Will Invest US$61 Million to Cleanup River Basins
For more information on Water and Wastewater Treatment Chemicals: World Market
http://home.mcilvainecompany.com/index.php/markets/27-water/449-n026-water-and-wastewater-treatment-chemicals
NORTH AMERICAN WASTEWATER TREATMENT PLANTSUPDATE HEADLINES
August 2014
ALABAMA
$1.6 Million for Equipment for Dothan WWTP
ARIZONA
Marana Wastewater Plant Upgrades
Tucson looking at Recycling Wastewater
Lake Havasu City requesting Bids for Wastewater Services
Grant to help Safford Recycle Wastewater
ARKANSAS
Springdale starts Study on Regional Sludge Processing
Pine Bluff accepts Bids for Wastewater Rehab Projects
CALIFORNIA
Riverbanks WWTP to replace Aerators
New Cost Estimates for Yucca Valley Wastewater Project
Holtville names HDR for Construction Management at WWTP
$140 Million for Visalia Water Plant
$7.5 Billion Water Bond could meet California's Water needs during Drought
CONNECTICUT
$25.8 Million for Killingly WWTP Upgrade
Derby needs WWTP Upgrade
FLORIDA
Orange County requesting Bids for Water/Wastewater Improvement Project
Hernando moving Forward with Airport Wastewater Plant Expansion
GEORGIA
$73 Million for Water/Wastewater Projects in Georgia
SRWMD gets Valdosta Wastewater Treatment Plant Update
ILLINOIS
$2.7 Million for New Tonica WWTP
INDIANA
Crown Point to replace Filtration System at WWTP
$3.2 Million for Jennings County Wastewater Treatment Project
Huntertown to build WWTP
IOWA
Luther facing Crunch to Solve Water Issues
Armstrong needs WWTP Upgrade
KANSAS
Hays Wastewater Facility getting Upgrade
KENTUCKY
Kentucky American Water acquires Millersburg Water/Wastewater Systems
Campbellsville requesting Bids for WWTP Chlorination & Dechlorination System
Improvements
MAINE
$1.5 Million for Eliot Wastewater Project
MARYLAND
Millersville requesting Bids for WWTP ENR Upgrade
MASSACHUSETTS
$2.5 Million for Colrain Wastewater Project
MINNESOTA
Lakefield seeks Grant for Wastewater Treatment Plant
MISSISSIPPI
Hattiesburg to proceed with Alternate Wastewater Plans
Holly Springs requesting Bids for WWTP Improvements
MISSOURI
Cape Girardeau works on Feasibility Study for Wastewater Plant Consolidation
Carthage approves Bond for WWTP Improvements
Little Blue Valley Sewer District requesting Bids for WWTP Rehab
$10 Million Bond for Bloomfield Water/Wastewater Project
$50 Million for Springfield Wastewater Repairs
MONTANA
$3.1 Million for Belt Town Water/Wastewater Projects
$200 Million for Springfield's planned Sewer Upgrades
MSD Project Clear will cost Billions
$1 Million for Pierce City WWTP Improvements
Cardwell approves Wastewater Bid
$40 Million for Hannibal WWTP Improvements
NEBRASKA
York planning Wastewater Project
NEW JERSEY
Brick Township requesting Bids for Wastewater Pump Station Rehab
$1.28 Billion for Water/Wastewater Projects for New Jersey
Bergen County WWTP to become Self-sufficient on Power
$260 Million for Passaic Valley WWTP Project
NEW MEXICO
Laguna requesting Bids for Pueblo of Laguna WWTP Replacement Project
$27 Million for Portales Wastewater Project
NEW YORK
NY AG reaches Clean Water Agreement with NYC
Westfield to receive $2.1 Million for Wastewater Treatment Project
Syracuse Requesting Bids for WWTP Project
Central Square will Upgrade WWTP Equipment
Lexington requesting Bids for WWTP
Sewer Projects in Dutchess County receive State Financing
Rosendale OKs WWTP Plan for Resort Project
NORTH CAROLINA
$19 Million Statesville Wastewater Expansion Progressing
Burlington Pipe replacement at WWTP to Begin
Lincoln County planning WWTP Expansion
NORTH DAKOTA
$105 Million for Williston WWTP Expansion
$77.4 Million for Minot WWTP
OHIO
Summit County, Twinsburg seek agreement on wastewater plant
$147 Million for Youngstown WWTP Upgrade
$88.2 Million for Phase 3 of Toledos Wastewater Project
Rocky River requesting Bids for WWTP Project
Youngstown needs Water/Wastewater Upgrades
$36 Million for Niles WWTP
Summit County approves $1.9 Million Wastewater Agreement with Twinsburg
Highland County approves Contract for Rocky Fork Wastewater Treatment Plant
Ohio to help Cities with Water/Wastewater Projects
Rossford discusses Water System
OKLAHOMA
$63 Million for Norman Wastewater Upgrade
OREGON
Myrtle Point and Powers plan WWTP Projects
PENNSYLVANIA
Bids too High for Lansdale WWTP Project
Johnstown moves forward with WWTP Upgrade
$50,000 for Engineering Study for Grove City WWTP
Lansdale to Rebid WWTP Upgrade
SOUTH CAROLINA
Pierre Wastewater Plant needs $1.66 Million in Repairs
SOUTH DAKOTA
Freeman reduces Scope of Wastewater Project
Hot Springs requesting Bids WWTP Propect
TEXAS
Montgomery requesting Bids for Interim WWTP Construction
Laredo requesting Bids to Build Sombreretillo WWTP
Waco requesting Bids for WWTP Lift Station and Force Main Design
$100 Million for New Braunfels WWTP Project
$32.5 Million for Killeen WWTP Improvements
UTAH
Logan, Cache County Planning $110 Million WWTP
VERMONT
Bellows Falls resets Wastewater Bond Vote
Randolph Wastewater Facility settles Water Pollution Violations
WASHINGTON
Washougal requesting Bids for WWTP Improvements
Carlsborg to send Wastewater to Sequim Plant
WEST VIRGINIA
$8.3 Million for Tazewell County WWTP
WISCONSIN
Wisconsin must Safeguard Drinking Water from Algae
CANADA
Edmonton requesting Bids for WWTP Equipment Upgrade
$72.6 Million for Moncton WWTP Upgrade
$72 Million for New Trenton WWTP
$5.2 Million for North Bay WWTP Upgrade
$10 Million for WWTP in Windsor
Canadian Government supports Water and Wastewater Infrastructure in New
Brunswick
BUSINESS NEWS
World Water Works to unveil New Bulking Sludge Management Technology at WEFTEC
2014
Hydro launches GritCup and SpiraSnail
World Water Works supplies DEMON Technology for Blue Plaines WWTP
Xylem launches Ozone-Enhanced Filtration System
RECENT CHEMICAL BID REPORTS
For more information on North American Municipal Wastewater Treatment Facilities
and People click on: http://home.mcilvainecompany.com/index.php?option=com_content&view=article&id=71#62ei
For more information on Water and Wastewater Treatment Chemicals: World Market
http://home.mcilvainecompany.com/index.php/markets/27-water/449-n026-water-and-wastewater-treatment-chemicals
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Bob McIlvaine
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847-784-0012 ext 112
rmcilvaine@mcilvainecompany.com
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