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.Tomeet 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 a
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
Flue Gas Desulfurization
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.
What are the impacts on the scrubber when ozone is injected ahead of the
scrubber for purposes of NOx capture?
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.
What is the best approach to control combustion to balance the efficiency and
pollution reduction goals?
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.
Sales of Ultrapure Water Systems Will Exceed $4.5 Billion Next Year
Sales of ultrapure water hardware and consumables will exceed $4.5 billion in
2017. East Asia will be the largest purchasing region. The electronics industry
will be the leading purchaser followed by coal-fired power plants. This the
latest forecast in McIlvaine’s N029 Ultrapure Water: World Market.
Ultrapure water systems have many components. A number of consumables are also
purchased. The largest selling products will be instruments and controls.
Condensate polishing systems come in second.
1 Instruments & Controls
2 Condensate Polishing Systems
3 Construction
4 RO Systems
5 RO Membranes
6 Filtration
7 Engineering
8 Pumps & Valves
9 Storage & Piping
10 Condensate Polishing Resins
11 IE Systems
12 Degasification
13 IE Resins
14 Heaters
15 Disinfection
16 Distillation
For more information on N029 Ultrapure Water: World Market, click on:
http://home.mcilvainecompany.com/index.php/markets/27-water/447-n029-ultrapure-water-world-markets.
Sales of Cleanroom Consumables Will Exceed $8 Billion Next Year
Cleanrooms will spend just under $8.2 billion for consumable items next year.
This is the latest forecast in World Cleanroom Markets. All the products which
are used in a clean environment differ from standard products in that they
cannot contaminate the cleanroom environment. East Asia will be the largest
purchasing region followed by NAFTA.
The semiconductor industry will be the largest purchaser followed by other
electronic segments. The pharmaceutical industry is relatively small, but has
its own unique requirements.
1 Semiconductor
2 Other Electronics
3 Pharmaceutical
4 Flat Panels
5 Other Industries
6 Hospital
7 Cleanroom Suppliers
8 Medical Devices
9 Food
10 Aerospace
11 Bioclean
Gloves will be the leading single revenue generator although numerous
miscellaneous supplies grouped together create a larger category. Cleanroom
laundries will generate revenues of nearly $1.5 billion. Since laundries often
rent garments, the laundry and reusable garment markets should be analyzed
together.
1 Supplies
2 Gloves
3 Laundry
4 Wipes
5 Reusable Clothing
6 Disposable Clothing
7 Paper
For more information on N6F World Cleanroom Markets, click on:
http://home.mcilvainecompany.com/index.php/markets/2-uncategorised/474-n6f-world-cleanroom-markets.
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
• Indiana Michigan Power adding Additional Emission Controls
• Idaho Power seeks to close Coal-fired Power Plant Early
• SRP to Test burning Forest Debris at Coal-fired Power Plant
• Murray issues Formal Layoff Notice for Powhatan 6 Coal Mine in Ohio
• Duke University Study finds Hexavalent Chromium is Not from Ash Basins
• Southern will need to reduce NOx during Ozone Season in Alabama and
Mississippi
• Arkansas Power Generators required to lower Emissions
COAL – WORLD
• Yaos, Energy China team up for $2-Billion Power Project
• Vietnam contemplates doubling Coal Export Quota to reduce Stockpile
• Hindalco (India) gets Government permission to use Petcoke at Power Plant
• Tanjung Jati B Coal-fired Power Plant Unit 5 & 6 Expansion Project in
Indonesia
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:
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