“Improvements to Precipitators” Will Be the Hot Topic Discussion on October
22
At 10:00 a.m. Chicago time on October 22, there will be an informal discussion
of many of the issues raised in recent issues of the Precip newsletter.
The subject of mid-frequency vs. high frequency power supplies is under debate.
NWL, Alstom and other suppliers have been joined by Longking which has its own
high frequency power controls. What are performance and cost differences?
Hybrid fabric filter/precipitators were developed by DOE NETL and licensed to
Longking in China. A large number of commercial installations are now in
operation. What are the performance and cost comparisons vs. either fabric
filters or precipitators?
Are hybrid precip/fabric filters the way to meet the 6 mg/Nm3 standards now
being imposed in China? The Chinese say wet precipitators are the answer. B&W
says a new wash system may minimize corrosion without needed expensive high
nickel alloys.
A recent refinery cat cracker precip explosion raises the question of whether
more can be done to improve precipitator safety.
Should the industry move to “Total Solutions.” Companies such as B&W can supply
complete systems and then all the repair parts as needed. Remote monitoring can
allow suppliers to provide continuous advice and support. The ultimate is the
service offered by FLS which includes total operation of a cement plant. What
are the trends and what should they be?
Power is the main but not only application for precipitators. What is the latest
in oil mist collection? Clarcor and KlEAN (a Chinese company) have new precip
designs for this application. Fabric filters have supplanted precips for many
applications in many countries. Where are precips being applied today? Steel
mill BOF furnaces in India, nickel smelters in Zimbabwe, pulp mills in Canada
and wood fired boilers in the U.S. are examples. Will precips continue to be
used for these applications?
To register or for more information click on: Click here to register
Why international suppliers should focus on the top 200 prospects (Arcelor
Mittal example)
Many companies recognize the importance of large customers and have assigned
personnel and resources to them. By providing precise forecasting and organized
information on large customers, this major opportunity can be maximized.
McIlvaine achieves this with the Detailed Forecasting, Large Project Tracking
Program. The important parameters are:
• The top 200 suppliers buy more than 60 percent of the products and services.
• A special program should be created to sell to this group.
• International suppliers have the best opportunity selling to large
international customers.
• International customers want global suppliers.
• Large customer are willing to pay higher prices for higher quality equipment
and services and are willing to expend the effort to make a total cost of
ownership evaluation.
• Precise forecasting by product, company and project coupled with timely
information will provide the supplier with the tools he needs.
The Arcelor Mittal example:
Arcelor Mittal is one of the top 200 flow control and treatment purchasers.
Arcelor Mittal produces 98 million tons of steel per year at 194 sites. It
produces twice as much as the nearest competitor or 6 percent of the 1.6 billion
tons of steel produced last year. It is also one the largest mining companies
with both iron ore and coal mining capacity. The company has production sites
around the globe making it one of the top 200 purchasers of flow control and
treatment equipment. Last year it purchased 1.3 percent of the fabric filters
and bags. It is a major valve purchaser with some plants operating more than
50,000 valves.
The company has adopted a global procurement program based on total cost of
ownership. This program launched in 2007 places emphasis on life cycle cost and
not initial price. It seeks long term relationships pooling knowledge and
deploying specialized technical knowledge. This means that companies with better
products have the opportunity to charge the prices commensurate with product
value. They also have an opportunity to provide global service to help ensure
the lowest cost of ownership.
Air programs: The company is focused on reduction of dust, NOx and SO2. The
capital investment in steel plant air pollution control projects in 2014 was
$180 million. Dust emissions were 621 grams per ton of steel produced which is
down 24% percent of the 2010 level. NOx emissions fell 4 percent in 2014 to 1.1
kg/ton of steel and SOx emissions decreased 3 percent.
Dust emissions from mining operations fell 6 percent to 5.3 million tons in 2014
while NOx fell 3 percent and SOx 26 percent (mainly due to a fuel change).
In 2014 ArcelorMittal R&D division worked on 13 air emission projects to improve
dedusting systems and also processes.
Water Programs: The steel plants use large quantities of water for cooling and
are located adjacent to lakes or rivers. Of 134 steel sites, 20 are located in
regions which are experiencing water stress or scarcity. As a result, the Global
R&D group is focused on water reuse and zero liquid discharge. The water
treatment laboratory in Asturias, Spain is investigating green technologies to
minimize pollutants.
Water at the mines needs to be treated before discharge. Water is also used for
dust suppression, transporting tailings and concentrating ores. Some mines such
as El Volcan in Mexico use special thickeners to avoid the use of tailing ponds.
The Indiana Harbor Works has installed a zero liquid discharge system (ZLD). The
Newcastle, S.A. site has just commissioned a $40 million facility to treat
wastewater. ZLD is already being accomplished at Saldanha and Vanderbijlpark.
Two mine water treatment plants are in design and construction in Kazakhstan. A
major water reduction program has been underway in Romania.
Arcelor Mittal in McIlvaine Program
Several McIlvaine project tracking systems cover the large ArcelorMittal
projects around the world.
Location Timing Project Description
Aviles/Gijon
Spain 2016-2019 Reconstruction of two of 45 coke oven batteries with collection
and scrubbing system.
Ghent, Belgium 2016-2017 $100 million bio ethanol plant using CO gas from steel
with eventual capacity of 47,000 tons of ethanol/yr.
Germany 2016 Minor projects in Bremen, Duisburg, Brandenburg and Hamburg
including galvanizing lines and new pre heat furnace.
Bosnia -Herzegovina 2015-
2016 New dust filters for BOF furnace with mid 2016 completion date. New filters
for sinter plant are already installed. Sinter machine #4 precip internals also
replaced.
Calvert Alabama 2015-
2016
$6.7 million for coating line with pumps and $40 million for slab yard
expansion.
Ostrava
Czech Republic 2014-2016 Valmet is supplying new CFB coal-fired boiler to
replace old existing coal-fired boilers. Fabric filters will be used for dust
capture.
Ostrava
Czech Republic 2014-2016 ZVVZ-Enven Engineering is supplying $25 million DeSOx
project and CKD Phraha is supplying a $50 million DeNOx system.
Hunan Valin
China 2014-2017 New $832 million automotive steel plant.
Acindor
Argentina 2013-
2017 400,000 ton/yr. rolling mill was initiated in 2013 with expectation of a
two year completion date. Five other production lines at the site produce 1.7
million tons/yr.
Dunkirk
France 2013-2015 New $110 million revamp of blast furnace #2 to be completed
this year.
There is also detail on specific plants.
ArcelorMittal Burns Harbor LLC
Unit ID: Hot Dip Coating Line Annealing Furnace Click on Unit ID to view
Emissions Data
Equipment: Selective Catalytic Reduction - SCR
Installation Year: 1999
Primary Contact Name: Robert Maciel Manager, Environmental Services
Telephone: 219-787-4973 E-mail: robert.maciel@arcelormittal.com
ArcelorMittal Cleveland Inc.
Unit ID: Boiler 3 Click on Unit ID to view Emissions Data
Operating Hrs. /Yr.: 8760 Fuel: natural gas, coal
Equipment: Electrostatic Precipitator
ArcelorMittal Indiana Harbor LLC
ArcelorMittal Lackawanna LLC
There are links to air and water permits with considerable detail on each
emitting source:
• Arcelor Monessen coke plant Air permit from 2014-2019 covering coke oven
pushing and quenching the desulfurization plant, the coke pushing baghouse and
benzene NESHAPS control system but an environmental group PennEnvironment is
suing the plant for emitting excess soot, acidic gases and noxious odors since
the decades-old facility went back into operation in April 2004.
• Minorca Mine Virginia City Minnesota air permit with requirements for fabric
filters and scrubbers used in the concentrating and pelletizing of 9 million
tons/yr. of taconite ore to manufacture 3 million tons/yr. of pellets.
• Weirton West Virginia 3 small oil- and gas-fired boilers air permit expires in
2016. A 2012 Title V permit expiring in 2017 covers the reheat furnaces, hot
strip mill pickling lines and HCl regeneration. An NPDES permit on the water
side covers 18 mgd of cooling water discharge and 9 mgd of treated wastewater.
• Dofasco Ontario facility paid $390,000 penalty in 2014 for excess blast
furnace emissions.
• ArcelorMittal Steel USA, Inc. - IN Harbor East, Permit No. IN0000094 - RENEWAL
covers iron & steel, rolling mill operations and finishing operations with
additional support operations: power generation, wastewater treatment with
discharge to the turning base and ship canal. Several storm water outfalls which
have the potential to discharge to these waters are also covered by this permit.
There are details on specific flow control and treatment products:
Pumps: Hydro descaling pumps are used at the Indiana plant. Weir received an
order for $2.8 million for Warman slurry pumps for tailings transfer at Krivoy,
Ukraine.
Sedimentation/Centrifugation: Dawco installed a 43m diameter thickener, a 25m
diameter water tank, a pump house building and a piperack that connects to the
concentrator sector of the Mount Wright Iron Mining Complex in Fermont, Québec.
Monitoring: CiDRA SONARtrac® Process Monitoring Technology is used for product
transfer measurement on a 27 km hydrotransport slurry pipeline in Mexico that
runs from nearby mines to steel plant in Lázaro Cárdenas City, Michoacán. A high
pressure pump injects the slurry into the steel pipeline for the 27 km transit
to the pelletizer plant.
Valves: ArcelorMittal Tubarão (formerly CST-Arcelor) Brazil, had Life Cycle
contracts with Metso for all automated control, manual and safety valves
throughout the ArcelorMittal Tubarão’s plant in Serra City. The total is almost
40,000 valves and included over 700 control valves.
In 2015, ArcelorMittal Tubarão, awarded SGS a four-year contract for the
maintenance of security and control valves. A specialist team of 30 experts will
detect the type of maintenance required for each valve. Valves will then be
removed, opened, serviced and reinstalled. If major repairs are required, the
valve will be taken to the dedicated SGS workshop in the city of Serra.
ArcelorMittal Gent is using 25 Econ-ARI Stevi® control valves and accessories
from Econosto in order to reduce power consumption in a series of heat
exchangers. With this investment, the steel producer expects to reduce its
energy bill by between € 60,000 and € 80,000 per year.
For more information on Detailed Forecasting, Large Project Tracking Program.
Contact Bob McIlvaine at: rmcilvaine@mcilvainecompany.com 847-784-0012 ext. 112.
Novel Uses of Renewable Energy
The Irvine Company announced an initiative to become the world's first major
real estate company to create a fleet of hybrid-electric buildings powered by
state-of-the-art energy storage systems from Tesla Energy. The company recently
signed a memorandum of understanding for the ground-breaking environmental
initiative with San Francisco-based Advanced Microgrid Solutions (AMS).
Large battery systems at each building—which take up the equivalent of about
five parking spaces—will be charged during nonpeak hours and be used, when
needed, for peak daytime use or in the event of a power failure. Stored energy
initiatives such as this one are part of Southern California Edison's (SCE's)
grid modernization plan.
The first phase of the Irvine Company project—which will include up to 24 office
buildings in Irvine— is expected to reduce peak demand in those buildings by 25%
and provide SCE with up to 10 megawatts of reserve capacity, enough to supply
power to 10,000 homes. The first energy storage units in Irvine are expected to
be installed by the end of this year.
Taiwan has unveiled the Eco-Power Station (EPS), a revolutionary, totally
off-the-grid system that is entirely self-powered by solar energy. It features a
5 kW thin-film photovoltaic module as well as a 5kW lithium-ion battery. The EPS
was designed by the Green Trade Project Office, which is Taiwan's leader in
promoting and integrating green products and services. Altogether, the Eco-Power
Station has brought together ten innovative Taiwanese green-technology producers
in order to demonstrate the viability of a green solution to the crisis of
climate change.
Basically, the EPS has been created out of a 40 by 8 foot shipping container
that will actually serve as an electric-bicycle station. In addition, the entire
rooftop area of the station is covered with GEAC's thin-film solar panels. These
panels feed the station's smart grid with electricity, with any excess
electricity then stored in the station's batteries.
In addition, while the renewable energy systems that power the station are
reliable and continuously monitored, the station has also installed M-Field's
hydrogen fuel cell to provide reliable backup power, in case of blackouts. Under
normal conditions, this hydrogen fuel cell self-refuels, when a supply is
maintained through the solar-power source. In total, this fuel cell can provide
more than 8 hours of back-up power while operating at its maximum output.
The EPS is scheduled to be shipped to Liberty State Park, New Jersey in March of
2016, to be used as one of the area's bicycle rental stations run by Bike and
Roll.
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
McIlvaine Hot Topic Hours and Recordings
McIlvaine webinars offer the opportunity to view the latest presentations and
join discussions while sitting at your desk. Hot Topic Hours cater to the end
users as well as suppliers while the Market Updates cater to the suppliers and
investors. Since McIlvaine records and provides streaming media access to these
webinars there is a treasure trove of value only a click away. McIlvaine
webinars are free to certain McIlvaine service subscribers. There is a charge
for others. Hot Topic Hours are free to owner/operators. Sponsored webinars
provide insights to particular products and services. They are free. Recordings
can be immediately viewed from the list provided below.
DATE UPCOMING HOT TOPIC HOUR UPCOMING MARKET UPDATES
October 22, 2015 Precipitator Improvements
Decision guide to dry, hybrid and wet electrostatic
precipitators for solid fuel combustion, refining and other
industries. Focus will be on improvements to the electricals
and components.
Click here to register
November 12, 2015
Dry Scrubbing
Expansion of the dry scrubber decision guide for power plants,
incinerators, and other applications involving SDA, CFB and
DSI.
Click here to register
December 3, 2015
NOx Reduction
Decision guide to selection of SCR and SCR systems,
ammonia injection, reagents, catalysts for power plants
refineries, incinerators, chemical plants and other applications.
Click here to register
----------
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