Webinar on September 8th is more than just NOx control for PacifiCorp
September 8th will be the fifth webinar for PacifiCorp. Why would McIlvaine
provide all this free service to a power plant? The answer is simple. McIlvaine
hopes this will demonstrate that the air pollution control industry does have
new and better solutions. Furthermore, we want to create recognition by the end
user that new technologies or new combinations of existing technologies may be
the best choice for the next project. International suppliers with strong
engineering, innovative attitudes and the willingness to keep improving their
products will thrive. Profit margins will be high and local companies in
countries around the world will not be serious competition.
McIlvaine happened to be at the right place at the right time and his company,
Environeering, with funding from Combustion Engineering, developed the first
commercial limestone scrubber. Within a few years Environeeering had developed
several new generations of scrubbers including the ultimate encapsulation design
where the entire gas stream is converted to bubbles and the duct used to soak up
the contaminants. Environeering was sold to a power plant boiler and system
supplier who promptly shut down all the research. Environeering teamed with
United Engineers and based on Environeering pulp mill scrubber systems installed
a two-stage scrubber system at Philadelphia Electric Eddystone. The HCl and
particulate were captured in the first stage and the SO2 converted to magnesium
sulfite in the second stage. The successful Eddystone installation was followed
by units at Cromby all of which operated for decades.
McIlvaine is quite confident that a version of the Philadelphia Electric design
with modifications made by incinerator scrubber system companies in Europe will
result in the best way to manufacture rare earths. HCl Scrubbing and Rare Earth
Recovery from Coal-Fired Power Plants and Gasifiers are the Perfect Marriage.
The potential profit and growth for a company who is first on the block to
supply these systems is huge.
The PacifiCorp NOx reduction project is ideal as a way to demonstrate the power
of the approach. It is large ($700 million with 4 x 350 MW boilers). It involves
marrying a large number of technologies in the front and back end. The
conventional approach to install SCR would be very expensive for old power
plants with limited expected lifetime. Most of the new ideas that are being
generated are going to be ultimately rejected. At first, the most attractive new
concept was catalytic bags. The new FLSmidth 33 ft. long catalytic bags would
just replace the existing bags. SBS or hydrated lime would eliminate the ABS
buildup. However, it now seems that the low temperature and SO3 formation around
the catalyst particles will be a problem. So this option is being taken off the
table. On the other hand, a catalyst supplier thinks he has the answer and so
possibly a test bag or two can be tried soon.
H2O2 to create NO2 ahead of the scrubber initially seemed to be a viable option.
But, apparently the NO2 is not as soluble as the N2O5 created by ozone. But what
about combining H2O2, a cheap reagent, with ozone. Maybe it is a bad idea. But
for every 20 ideas there may be one good one.
Combining existing and developing technologies is probably going to be the only
alternative to SCR. The optimization approaches of GE, Siemens, Emerson and
Doosan promise some significant NOx removal. Combustion modifications and SNCR
could additionally supply enough reduction so that ozone injection ahead of the
existing scrubbers will further reduce NOx to 0.06 lbs./MMBtu. Innovations such
as combining H2O2 and urea as a reductant could also be beneficial. This is
being discussed on September 1 and will be revisited on September 8.
There is a fair chance that the series of webinars will lead to a solution for
PacifiCorp which is unique and represents an advancement of technologies. This
receptive approach will create a profit generating opportunity to those
suppliers who are on the cutting edge.
Click here to Register for the Webinars
The Catalytic Filter will have a Major Impact on the Fabric Filter, Scrubber,
Precipitator, NOx and FGD Markets
The catalytic filter has the potential to change air pollution markets in a
major way. Catalytic filters remove both NOx and particulate in one device. Over
the last 10 years they have slowly gained acceptance in many small applications.
The first large scale commercial installation in a cement plant is undergoing
testing. Coal-fired power plants are now evaluating this technology for some
near-term large projects. Because the catalytic filter can be used in
conjunction with direct sorbent injection, it can remove the acid gases, NOx,
and fine particulate. It can operate at 350oF with long fiberglass bags or at
850oF with shorter ceramic fiber bags. By combining three pollution control
devices into one, a large power plant could save more than $200 million in up
front capital expenditures.
Market Current Revenues $ Billions Potential Impact % Type of Impact
(positive +, negative -)
Fabric Filter 13 60 +
NOx Control 18 50 -
FGD (Power) 3 40 -
Scrubber (Industrial) 7 20 -
Precipitator 6 20 -
Heat Recovery 10 50 + -
It is early in the growth cycle so it is unclear who will be the big winners and
losers. Fabric filter system suppliers such as FLSmidth can capture the lions
share of the revenue. On the other hand, the catalyst suppliers such as Haldor
Topsoe can play either a minor or major role. System suppliers such as
Mitsubishi/Hitachi can also seize the opportunity. So far the most active
participants have been the Filtration Group, Tri-Mer, FLSmidth and Haldor Topsoe.
Both industrial scrubbers and power plant flue gas desulfurization (FGD) markets
will be impacted. The lower capital cost of the catalytic filter with direct
sorbent injection will have to be weighed against salable byproducts such as
gypsum. The negative aspect of the DSI/catalytic filter is the mixture of dust
and sulfates. In general, the large power plants with a likely buyer of
wallboard quality gypsum will want to stick with the present wet FGD. However,
suppliers of dry FGD systems could see their market disappear.
One of the biggest impacts will be on heat recovery. If the conventional air
pre-heater suppliers were to deal with clean hot 850oF gas, they could redesign
their units to eliminate most of the air in leakage and can also offer
economical designs to extract most of the rest of the heat in the flue gas.
Reducing the outlet temperature to 150oF instead of 350oF would improve power
plant efficiency by as much as 2 percent.
Each of the McIlvaine market reports is evaluating the impact of this new
technology. Also the Power Plant and other Decision Guides for end users are
providing intensive coverage of the technical developments.
1ABC Fabric Filter
2ABC Scrubber/Adsorber/Biofilter Knowledge Systems
3ABC FGD and DeNOx Knowledge Systems
4ABC Electrostatic Precipitator Knowledge Systems
N035 NOx Control World Market
44I Power Plant Air Quality Decisions
Yes, Landfill Gas Engines Will Produce More Poison Ivy but also More Tomatoes
A New York Times article warns of the impending growth of poison ivy. Yes, but
this fertilization effect of CO2 has been put to good use by thousands of
greenhouses around the world. GE, Cummins and other engine manufacturers are
actively pursuing CHP projects which provide greenhouses with electricity, heat,
light and CO2. Is it better to increase the production of tomatoes or retard the
growth of poison ivy?
The Southcoast Air Quality Management District (SCAQMD) struggled with this
question in the recent analysis of the 1110.2 biogas emission amendment. The
question is whether landfill gas engines would be a better choice than just
flaring. The Beverly Hills estate owner who can easily buy whatever tomatoes are
desired but is struggling to keep poison ivy under control will have a
completely different value judgment than a starving child in Sudan. Should
SCAQMD prioritize the desires of its residents above those of the starving
people in the world? The answer is Yes. But this does not mean that every
government in the world should reflect the values of SCAQMD residents.
There is a broader implication which greatly affects the market for
reciprocating engines. These engines contribute to the increase of CO2 in the
world. A recent study by a number of collaborating universities now supports the
long held theory that the earth is growing greener. Other studies have estimated
that the increase in crop value is in the $billions and possibly even the
$trillions. Many engines are being purchased by developing countries to provide
critical power and, in turn, save lives and increase the welfare of the
residents.
Decisions about the environmental impacts of these initiatives are being made on
a simplistic basis. Engine manufacturers should support a more complex analysis
which better represents the true desires of citizens. The three key analysis
elements are (1) quality of life, (2) tribal values and (3) discounted future.
The evaluation should not be based on the standard life quantity guide but on
life quality. The highest honor gold medal goes to the soldiers who sacrificed
decades of life quantity for one heroic life quality moment.
The tribal value question is put to rest by the fact that no government provides
more than a tiny fraction of a percent of GDP for foreign aid. The SCAQMD biogas
analysis reflects the values of the district. It points out that the CO2 from
flaring and the biogas engine are the same but that organic emissions could be
higher with the engine option. Since the SCAQMD residents are the ones primarily
impacted by the organic emissions, there is a tribal consideration which is
contrasted to the CO2 which is global.
The analysis further points out that the potential lost electricity with the
flaring is not consequential because the electricity furnished in the district
is efficient and green. By contrast, the starving Sudanese child lives in a
district without any electricity. The potential to convert flared gas into
electricity has enormous benefits to the child and other residents of the
district.
The third element is the discount rate for future values. The parents of the
Sudanese child and the wealthy grandfather setting up trusts are discounting
future values at greatly different rates. The value of one more tomato today vs.
one 50 years from now to the wealthy grandchild and the Sudanese child is very
different. This discount rate is at the heart of the controversy between the
Chinese government and international environmentalists. China has a program
which will convert large amounts of coal to clean gas. Sinopec is building a $20
billion pipeline to distribute this gas throughout China. Many engines will be
required to drive the thousands of compressors in the pipeline. The gas will
replace solid fuels burned in many residences. China believes that this cheap
gas supply will result in eliminating the severe smog problem. The health of
Chinese citizens today is being prioritized over worldwide health consequences
fifty years from now.
There is no simplistic answer in choosing between poison ivy and tomatoes. The
world deserves the more complex analysis explained at Sustainability Universal
Rating System.
Details on the technical, commercial, and application information on the use of
engines for greenhouses, pipelines, compressors, data centers and wastewater
plants is available through a service described at GTRE Decisions.
The markets, regulations and competitive information is in a program described
at 59EI Gas Turbine and Combined Cycle Supplier Program
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
#1287 August 26, 2016
Table of Contents
COAL US
NIPSCO considering closing Coal-Fired Units
NIPSCO to demolish Dean H. Mitchell Station in Gary, Indiana
Montana City seeks to limit Water use to help Coal-fired Power Plant
Four Coal Plants to stay Open and comply with EPA Regulations
US DOE invests US$28 Million to advance Cleaner Fossil Fuel Power
Mon Power and Potomac Edison invest in Environmental Controls at Harrison and
Fort Martin Power Stations
GASIFICATION
Indiana Regulators approve Deal over Coal Gasification Power Plant
COAL WORLD
TaiPower's Linkou Ultrasupercritical Coal-fired Units under construction
Walhi opposed to Bengkulu Coal-fired Thermal Power Plant
Dubai invests in Clean Coal Project
India asks Government-owned Power Plants to stop importing Coal
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
September 1, 2016
11:30am CDT PacifiCorp Webinar 4 on back end NOx removal - Review of options
from webinar 3 to determine suitability of catalytic filters, Sorbocal injection
for ABS control, H202 with SNCR, in duct catalyst, raising air heater
temperature and fan adjustments.
September 8, 2016
11:30am CDT PacifiCorp Webinar 5 on front end NOx reduction - Review of options
for NOx reduction including combustion modifications, reburn, SNCR, and
optimization with review of previous presentations of Emerson, Doosan, Siemens
and GE. A number of case histories, now being posted to PPAQD, will also be
reviewed. Summaries of phone calls to end users may also be included.
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:
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