FGD and DeNOx NEWSLETTER

· John Crane Seal Maintenance Program improves Pump Cost of Ownership In German Lignite-fired Power Plant

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The power industry’s annual spending for SCR systems, catalysts and reagents will rise modestly from $9 billion this year to $10 billion in 2029. Sixty-seven percent of the purchases will be for Asian power plants.

There are presently 2 million MW of coal-fired plants installed worldwide. This includes 1.2 million MW of SCR installations. There will be 30,000 MW of SCR retirements in the next decade. The coal fired base will increase by 270,000 MW in the next decade of which most will require SCR. This means total SCR will increase by 230,00O MW to over 1.4 million MW over the next decade.

Expenditures for new SCR systems will be $20 billion or over $2 billion/yr. Expenditures for reagents will rise from $5.2 billion per year to over $6 billion. The yearly increase will be over 3 percent. The purchase of SCR catalysts will rise from $1.7 billion per year to over $2 billion by 2029.

More than 50 percent of the coal-fired NO_x control systems are in China. With the Guodian-Shenhua merger the combined company operates 14 percent of the world’s coal-fired power SCR systems. It is the leading purchaser of NO_x control equipment but is also a supplier to other utilities.

Catalyst and Reagent Purchases $ millions - 2019
Company	Reagent	Catalyst
Datang	423	139
Guodian/Shenhua	726	238
Huaneng	544	179
Huadian	363	119
NTPC	189	62
ENEL	60	37
J-Power	30	10
KEPCO	142	46
AECOM	57	19
AEP	66	22
BWE	36	12
Duke	60	20
NRG	60	20
Southern	60	20
Vietnam Power	121	40

Most purchasers are spending far more for replacement catalyst than for new catalyst. The exception is NTPC who is installing many new SCR systems.

In the year 2000 China was importing nearly all the catalyst it required. Today the Chinese catalyst producers supply sufficient catalyst to meet domestic needs and also supply catalyst for export.

One of the future opportunities for international suppliers is the supply of catalytic filter elements. Haldor Topsoe and Filtration Group are leading the way with this important new technology which allows NO_x reduction and particulate capture in the same device.

There are multiple tracking systems to identify each new project. A weekly Utility E-Alert provides the latest insights. The individual services which can be part of a package are linked below.

Coal-fired power represents the largest single opportunity for suppliers of combust, flow and treat (CFT) equipment. The replacement and repair for existing plants far exceeds that of any other application. There is so much new plant construction in Asia that coal-fired generators remain the leading purchasers of new systems and components. The market is very challenging for CFT suppliers because the geographies and decision makers keep changing.

Who would have predicted that in terms of CFT products for new plants the U.S. would not be in the top 50 countries and that India, Vietnam, Indonesia and Turkey would be near the top behind China? Who would have predicted that China would have tougher standards for the combination of greenhouse gases and air pollutants than any other country?

Non-Chinese suppliers of instruments, valves, pumps, nozzles, seals, mist eliminators, filter bags, precipitator rappers and DeNOx catalyst have to be innovative to keep leadership positions when more than 50 percent of the market is in China. The emergence of Chinese coal fired generator and APC system suppliers on the world stage has both negative and positive implications for the international CFT suppliers. The negative aspect is that the suppliers will tend to use Chinese components. The positive aspect is that many of these companies are now supplying build, own, operate systems. If an international supplier has the lowest total cost of ownership (LTCO) product then he has a chance to sell to Chinese system suppliers who are charging owners a fixed price per kW.

This opportunity can be seized with the aid of tools developed by the McIlvaine Company which are outlined in the Most Profitable Market Program explained at www.mcilvainecompany.com

The future is in total solutions. A valve or a pump is no better than the way it is used in a system. Many of the opportunities will take place in countries where the supplier does not have a strong sales presence. Working with local entities is one option. Another is to collaborate with other suppliers of complimentary products and jointly chart a sales strategy for a particular country. McIlvaine will be participating in a half-day session at PowerGen to discuss these options.

In many cases the supplier already has representatives or company personnel in the target country. These people can be most effectively used by busting the geographical and application silos. These people can become more effective if there is a forecast of the product sales potential at each major prospect. In most cases a successful sale needs the efforts of multiple people at disparate locations. Maximizing their contribution is a goal of the SiloBuster program.

Success is contingent on providing the lowest total cost of ownership (LTCO) and then validating it (LTCOV). With remote monitoring and data analytics the cost and performance of each CFT product will be tracked. Suppliers need to understand the processes, adapt their products to make them superior and then validate this superiority through all the means available including exhibitions, media and some innovative routes to market as explained in 44I Coal Fired Power Plant Decisions.

Purchases at each large power plant are large enough that a specific revenue opportunity can be generated and a program to pursue it put in place.

A complete profile on EVN as well as every major utility is provided in the Utility Tracking System along with capacity in MW for thousands of operators and 15,000 individual units.

The Utility Tracking System 42EI Utility Tracking System provides coal fired capacity forecasts for each country. The capacity will increase from 2 million MW to close to 2.3 million MW between 2018 and 2022. For some countries such as Belgium coal has been phased out. But for others such as Bangladesh there will be sixteen times as much coal-fired capacity in place in 2022 as in 2018.

Coal Plants by Country (MW) Installed Base
Country	2018	2019	2020	2021	2022	2023	2024
Albania	0	0	0	0	0	0	0
Argentina	350	350	350	350	350	350	350
Australia	24,442	24,442	24,442	24,442	24,442	24,442	24,442
Austria	635	635	635	635	635	635	635
Bangladesh	525	1,200	2,500	5,500	8,000	10,000	12,000
Belarus	0	0	0	0	0	0	0
Belgium	0	0	0	0	0	0	0
Bosnia & Herzegovina	2,073	2,073	2,073	2,073	2,073	3,000	4,000
Botswana	600	600	732	732	732	1,200	1,200
Brazil	2,804	2,804	2,804	2,804	2,804	3,400	3,400
Bulgaria	4,889	4,889	4,889	4,889	4,889	4,889	4,889
Cambodia	505	505	505	505	1,200	1,200	2,000

The Alert 41F Utility E-Alert provides project news. Background details can be found in the tracking system database. The SiloBuster program can be used to coordinate the sales effort. The revenue forecast for specific products at each plant provides a long-range tool for which this updated information is just a small piece of the puzzle. The program is geared to provide maximum value to those suppliers selling high performance products. Success comes with a long-term program which convinces the customer to include the supplier on a bid list whenever the opportunity arises.

Although the coal-fired market is challenging the Most Profitable Market Program provides a route to market to maximize success. For more information on the program contact Bob McIlvaine 847-784-0013; rmcilvaine@mclvainecompany.com.

Subscribers to McIlvaine market reports and databases can now take advantage of a free 90-minute webinar opportunity where individuals from multiple product groups, locations, and disciplines can review displayed data, ask questions and provide insights.

In “The Silo Effect,” Gillian Tett documents the magnitude of the problem created by the efficient division of labor. Surveys show that management ranks lack of collaboration among divisions as a top problem. CFT companies such as IDEX and Filtration Group have become very successful by encouraging each product group to operate independently. You cannot argue with success. But as Tett shows with her examples there is much additional benefit in communication among disparate groups. The challenge is to do this without restricting the independence. The SiloBuster webinar program is a good way to initiate this collaboration.

McIlvaine market reports have forecasts for each product in each industry in each country. This empowers people with local sales knowledge to contribute. Representatives and distributors can be allowed to view data during the webinar and make contributions. The reports also have the forecasts for each large customer. The database reports have the details on the specific corporate customers and plants.

The data also includes forecasts of present and future production in each industry and country. For example, there are forecasts in MW for solar, gas turbine, coal, and nuclear power. There are forecasts in tpy or m³ of ethylene, LNG, and other petroleum products, wafers per month for semiconductor companies, production in tpy for each type of ore, wastewater treatment in MGD, and square feet of pharmaceutical cleanroom space. This level of detail empowers people with specific knowledge to contribute.

Many distributors or representatives have unique industry knowledge. There are many rapidly developing markets such as single use biopharmaceuticals, hydraulic fracturing in Argentina, China and Saudi Arabia, ultrasupercritical coal-fired generators in China, lithium production in Australia, and manufactured frac sand production in Texas. Input from various individuals will contribute greatly to better understanding these new developments.

Many purchase decisions are made at the corporate level. BASF in Germany has standardized on condition monitoring flow measurement from companies such as E&H. These guides apply to all the hundreds of BASF plants around the world. Arcelor Mittal is buying fabric filter systems in Belgium for operation in South America. In Chile Suez operates half the municipal wastewater plants with purchasing guidance from France. This internationalization makes it highly desirable to pursue each large customer on a collaborative basis.

One of the biggest opportunities is to understand and leverage the product technology of the disparate groups. With IIoT and Remote O&M the emphasis is on the total cost of ownership of the system. A smart pump or valve is better than a product of equal quality which does not perform smartly. The pump is dependent on the valves operating optimally. The scrubber operation is dependent on the pump. In the case of FGD the fan and pump are sharing work. There is the option to increase the fan horsepower for more efficient scrubbing with less pump flow. The use of HEPA filtration for gas turbine inlets reduces turbine wear and greatly increases the HEPA market. Many of these technology developments are included and can be viewed during a webinar in http://home.mcilvainecompany.com/index.php/other-services.

Understanding the relationship of all these products is challenging. Each process in each industry provides its own unique requirements. Within a large corporation there are industry specialists. In addition, there are employees who formerly were employed by a company in the subject industry. Their knowledge can be beneficially extracted.

Competitor knowledge is spread across many individuals within the organization. McIlvaine reports have estimated market shares. These can be the basis for group discussions. Some competitors will have new products or have been merged with another company. When TLT was purchased by POWERCHINA with $48 billion in sales and a double-digit growth rate it changed the Chinese market opportunity for Howden and other fan companies.

Sharing information about regulations is also important. China has an HELE (high efficiency, low emissions) initiative. Part of that initiative is third party operation of power plant air pollution systems to insure compliance. This creates a whole new group of purchasers of lime, nozzles, agitators, fans, dust collector bags, valves, pumps, couplings, seals, water treatment chemicals etc. Will these companies become international (Boqi is already expanding)? Will the initiative be copied in other countries?

One free 90-minute SiloBuster webinar is available for purchasers of the fabric filter, scrubber, FGD, DeNOx, thermal oxidation, precipitator, liquid filtration, sedimentation, IIoT & Remote O&M, valve, pump, and treatment chemicals reports. http://home.mcilvainecompany.com/index.php/markets

Another free webinar is available for purchasers of each industry report and database: coal, nuclear, gas turbine, renewables, oil & gas, water/wastewater, cleanrooms, semiconductor, pharmaceutical, industrial (including chemical, mining, pulp & paper, other). http://home.mcilvainecompany.com/index.php/databases.

With the various free webinars and others which can be added at a nominal price, a continuing SiloBuster webinar initiative can be undertaken. This initiative will be a catalyst for further intra divisional activity. For more information on this opportunity please contact Bob McIlvaine at 847-784-0013 or email him at rmcilvaine@mcilvainecompany.com.

JNG (Jiangnan Environmental Protection Group Inc.) is a leading pollution control company and will soon become the world's largest producer and seller of sulfur-based compound fertilizers. JNG provides flue gas desulfurization (FGD), denitrification, particulate control, acid gas treatment and FCC flue gas treatment solutions with advanced integrated engineering, patented equipment construction and operation services.

JNG also integrates ammonium sulfate resources to provide customized sulfur-based compound fertilizer for agricultural use.

In a recent E-Alert, we wrote about the JNG initiative to manufacture ammonium sulfate at plants in Illinois.

JNG has delivered more than 300 ammonium sulfate FGD systems. We are providing a link to 156 of them. Some of the larger systems are listed below. The name, size and particulate limits are provided. http://www.global-jng.com/projects.shtml

Client Name	Capacity MW	Outlet SO₂ (mg/Nm³)
Zhongtian Hechuang Erdos Co., Ltd.	5×150MW+1×70MW	＜75
Gulang Xinmiao Company	2×150MW	≤100
Shenhua Coal-to-oil Chemical Co., Ltd. Xinjiang Chemical Branch	4×150 MW	≤50
Xinjiang Markor Chemical Co., Ltd.	3×30 MW+3×60 MW	≤50
Xinjiang Xinlianxin Energy & Chemical Co., Ltd.	3x50 MW	≤50
Inner Mongolia Yitai Chemical Co., Ltd	4x150 MW	≤100
Henan Jinkai Chemical & Investment Group Co., Ltd.	2x150 MW	≤65
Wanhua Chemical (Ningbo) Thermal Power Co., Ltd.	1x150 MW	≤50
Power Plant of Sinopec Qilu Petrochemical Co., Ltd.	4x135 MW	≤50
Ethylene Plant of Sinopec Qilu Petrochemical Co., Ltd.	2x135 MW	≤50
Shenhua Ningxia Coal Group Co., Ltd.	10x200 MW	≤50
Yitai Xinjiang Energy Co., Ltd.	6x150 MW

The company has also installed SNCR and particulate control systems. Here are three examples:

This project is the main project of the Phase II expansion project of Wanhua Chemical (Ningbo) Thermal Power Co., Ltd., Ningbo Daxie development zone. It is 1 x 410 t/h CFB boiler flue gas denitrification unit. This project adopts the selective non-catalytic reduction denitration (SNCR) technology, the design of the denitration efficiency is no less than 55 percent, uses aqueous ammonia as the reducing agent, outlet NO_xis not more than 100 mg/Nm³, ammonia slip is less than 8 mg/Nm³, and denitration unit lifetime is not less than 20 years.

The scale of this project is 4×130 t/h sub-high temperature pressure circulating fluidized bed (CFB) boilers. Ningbo Jiufeng Power Co., Ltd. is a regional centralized heating and thermal power plant. The thermal load is relatively stable, and the operation mode of the thermal power plant is determined by thermoelectric and cogeneration. The #1-#3 boilers flue gas denitrification units adopt the SNCR + SCR combined denitration process. The NO_x concentration at the denitrification inlet is 300 mg/Nm³. Denitrification efficiency guaranteed value is ≥ 75 percent. #4 boiler uses SNCR technology alone, and the denitrification efficiency guarantee value is ≥ 60 percent.

The project is a 4×470t/h coal-fired boiler denitration retrofit project for the Phase I of the

power zone of the Datang International Keshiketeng Coal to Gas Project in Inner Mongolia.

The project adopts SCR, the NO_x content of the denitrification reactor inlet is 400mg/Nm³, the

NO_xcontent of the outlet is 80mg/Nm³, and the designed denitration efficiency is not less than

Neurath operates two brown coal power station blocks. Each of these power station blocks has a gross output of 1100 megawatts and an efficiency factor of more than 43  percent The core of the system for FGD gypsum dewatering consists of two 35-meter-long and 3.50-meter-wide vacuum belt filter installations from FLSmidth. With a total filter surface area of 93 m² each, they are counted among the largest FGD belt filters in the world. For many years FLSmidth has been relying on FGD gypsum filter cloths in VACUBELT belts from GKD. This is why in 2008 the two new blocks in Neurath were specifically equipped with the double-layered VACUBELT 2025 filter belt.

ThyssenKrupp Fördertechnik (TKF), has been using this belt type in various vacuum belt filters for FGD gypsum dewatering in the Rheinhafen-Dampfkraftwerk Karlsruhe, Datteln 4 and Maasvlakte (Netherlands) mineral coal power stations and in the Belchatov (Poland), Turcini (Romania) and Maritza II (Bulgaria) brown coal power stations.

The Belchatov power station with 12 blocks, is a large brown coal power station, It supplies a total output of 4400 megawatts of electricity. ThyssenKrupp Fördertechnik had already equipped six of the blocks in years past, of them four with complete belt filter systems and two with hydrocyclones. TKF was commissioned with equipping the 13th block to produce another 850 megawatts of electricity. Three vacuum belt filters with 55 m² of filter surface area each were installed here in 2011. TKF equipped all three with VACUBELT filter belts. The 2015 belt type has a high air flow rate and the dewatering effect is optimized the belt can be easily cleaned by spray pipes. Thanks to its extreme mechanical sturdiness, the VACUBELT 2015 can be adjusted to a speed of operation in line with demand. An advantage that proves its worth with major flexibility in throughput times and nominal thickness as regards non-contract specific feeding quality for gypsum suspension in particular. Immediately the continuous density measurement detects aberrant solid matter concentrations in the flue gas scrubber, the system will automatically run faster or slower in order to achieve unalterably good results. The spreader vanes typical of TKF systems in suspension feeding also ensure uniform spreading of the gypsum suspension and unvarying dewatering efficiency even at different speeds. Belt filters equipped with VACUBELT 2015 belts reduce residual gypsum moisture permanently to under 10  percent and at Belchatov produce 45 tons of product per unit per hour.

John Crane Seal Maintenance Program improves Pump Cost of Ownership In German Lignite-fired Power Plant

A German power plant experienced premature wear and excessive seal corrosion in its boiler feed circuit and flue gas desulfurization slurry pumps. By upgrading the performance of the pump seals and implementing a high-performance seal maintenance, repair, and part stocking program, unplanned pump shutdowns were eliminated and mean time between repairs improved from 20 to 40 months.

A critical component necessary to restoring and maintaining the integrity of the plant’s pump seals was the establishment of a program for ongoing seal inspection, maintenance, repair, and part stock management. And it needed a 24×7 stocking program that would integrate with its existing enterprise resource planning (ERP) system. To facilitate organization and structure in this area, John Crane implemented its Performance Plus Reliability Program, called Interface, for management of the plant’s mechanical seals.

All failures from existing seals are now immediately sent to a nearby John Crane service center for 24×7 repair. Dedicated spare parts are available 24×7 as part of the product/stock standardization program. The mechanical seal service delivers new John Crane seals and seal components to the plant, eliminating delays, and inefficient and faulty repairs. Additionally, training was provided to onsite field engineers and operations personnel to reduce the risk of unplanned downtime and recurring issues in the future.

Recently, SGB signed a contract for desulfurization pumps with China Power Investment Corp. for a Turkey power plant. China Power Investment Corp. has designated SGB as their desulfurization pumps spare parts supplier.

SGB signed a technical agreement of desulfurization pumps with SINOSTEEL Corp. for a Russian company. SINOSTEEL Corp. and the Russian company are partners. The two companies work together on flue gas desulfurization projects.

In 1989, SGB began designing high-efficiency slurry pumps. In the beginning, domestic customers doubted the quality of slurry pumps manufactured by SGB. In order to verify pump quality, SGB arranged a comparison of SGB slurry pumps with imported pumps, running in one system at the same time; the result was very favorable. The slurry pumps demonstrated high efficiency, low noise and stable operation. The SGB slurry pumps running efficiency reached over 75 percent. Pump life also compared favorably. As a result, the SGB pumps are widely applied in many industries such as ash handling systems in coal-fired power plants, mining beneficiation systems, chemical processes, river dredging, environmental protection power plant desulfurization systems, etc. In 2006, SGB achieved more than 75 percent market share in the coal industry and 50 percent of domestic slurry pump market share; SGB became the leader of China slurry pumps and replaced imported pumps successfully in the Chinese market.

Kunming Kunshui Industrial Pump Co., Ltd. ("Kunshui pump) is a manufacturer of slurry pumps with more than10 years’ experience in China. The Kunshui pump factory is located at Kunming, Yunnan province, covering an area of over 34,000 square meters. Kunshui Pump has installations in power and mining. This includes the following power plant FGD system.

Under the original Consent Decree, entered by the Court on December 10, 2007, American Electric Power Service Corp., et al. (AEP) agreed to substantially reduce sulfur dioxide (SO₂) and nitrogen oxides (NO_X) emissions from the AEP Eastern System that was then comprised of sixteen coal-fired power plants. As part of the original Consent Decree, AEP was required to install flue gas desulfurization (FGD) technology to reduce SO₂ on two electric generating units located at AEP’s Rockport, Indiana power plant. The original Consent Decree required AEP to install FGD technology on Rockport Unit 1 by December 31, 2017 and on Rockport Unit 2 by December 31, 2019. The Consent Decree’s requirements for Rockport Unit 1 and Rockport Unit 2 were later modified by the Third Joint Modification to the Consent Decree that was entered by the Court on May 14, 2013. Under the Third Joint Modification to the Consent Decree, AEP was required to retrofit, refuel, or re-power one Rockport Unit by December 31, 2025 and the second Rockport Unit by December 31, 2028.

Under the proposed Fifth Joint Modification to Consent Decree, the deadline for AEP to retrofit, refuel, or re-power Rockport Unit 1 is extended until December 31, 2028 and the requirement to retrofit, refuel, or re-power Rockport Unit 2 is removed. In exchange, AEP agrees to do the following: (1) Install enhanced dry sorbent injection technology to reduce SO₂ emissions on Rockport Unit 1 by December 31, 2020 and Rockport Unit 2 by June 1, 2020; (2) comply with a 30-day rolling average emission rate of 0.15 pounds of SO₂ per million British thermal units of heat input at the Rockport Units for years 2021 and beyond; (3) reduce the AEP Eastern System-wide annual tonnage limitations for SO₂ for years 2021 and beyond; (4) reduce the Rockport Plant- wide annual tonnage limitations for SO₂ for years 2021 and beyond; (5) install selective catalytic reduction NO_x control technology on Rockport Unit 2 by June 1, 2020; (6) comply with a 30- day rolling average emission rate of 0.09 pounds of NO_x per million British thermal units of heat input at the Rockport Units for years 2021 and beyond; (7) reduce the AEP Eastern System-wide annual tonnage limitations for NO_x for years 2018 and beyond; (8) provide the State Co-Plaintiffs with an additional $4 million in mitigation funding; (9) provide the Citizen Co- Plaintiffs with an additional $3.5 million in mitigation funding; and (10) retire Rockport Unit 1 by December 31, 2028.

Bob Giglio and Asif Hussain of Sumitomo SHI FW writing in the May issue of Modern Power Systems make a good case for CFB dry scrubbing for Indian power plants. They reinforce the maxim that all comparisons of scrubber cost of ownership are site specific. McIlvaine has excerpted from the article but also added questions in italics.

By 2022, SO₂ emissions for all operating plants in India that are 500 MWe or larger must not exceed 200 mg/ Nm³ and all new coal-fired power plants, regardless of rating and other special category plants, must meet even tighter SO₂ limits of 100 mg/Nm³. For an existing coal-fired power plant with baseline SO₂ emissions ranging from 1200 to 1400 mg/ Nm³ this amounts to an 80-90 percent SO₂ emissions reduction from uncontrolled levels.

The quality of gypsum produced in the typical Indian power plant has been poor due to the low purity (<80 percent) of local limestone. Additionally, the Indian market for gypsum is also saturated so the expected income stream from the sale of gypsum has been replaced with a recurring expense of large-scale gypsum disposal. (Is this a long-term situation? Elsewhere FGD gypsum has been successfully manufactured and sold).

In addition, water usage by wFGD is 30 percent to 40 percent higher than either the SDA or dry CFB scrubber options, which poses a challenge for plants built in drier parts of India such as Rajasthan, Gujarat, and Tamil Nadu, where water supplies for power generation are limited. Furthermore, a plant with a wFGD system must significantly increase operating, maintenance, and laboratory testing staff because the wFGD option is much more manpower intensive, particularly with respect to routine maintenance. For a country like India that has little to no experience with the installation, maintenance, or operation of modern air quality control systems, particularly FGD, this can be a challenge. (What about third-party operation such as now becoming popular in China?)

According to SHI FW CFB, a scrubber has an installed cost approximately 60 percent of a similarly sized wFGD system. In India, the average installed cost of a wFGD system has averaged $65/kW, this would translate into immediate savings of almost $25/ kW in favor of a CFB scrubber.

There are other important cost advantages with the CFB scrubbers say the authors. Because it does not need high-speed rotary atomizers within the absorber (requiring a high frequency of maintenance since they are prone to erosion, scale formation, and plugging) or lime slurry preparation equipment, annual maintenance is reduced by a factor of four compared to the SDA and even more so compared to the wFGD. (SDA suppliers will probably not agree and cite 50 years of atomizer experience).

CFB scrubber systems have been employed at plants worldwide firing coal with a wide range of sulfur levels with no technical limit on the entering fuel sulfur content, unlike the alternative technologies discussed above. (This is strong point for CFB but SDA suppliers now offer DSI plus SDA to increase the sulfur range, which can be encountered).

Fuel ash content seen in Indian fuels, up to 40-45 percent, is perfectly acceptable to a CFB scrubber. Also, the flue gas temperature does not limit the amount of lime injection as it does when using a SDA. This feature allows a significant increase in acid gas scrubbing performance, should future air emissions regulations require it.

This flexibility is an important performance characteristic for those plants receiving coal from mines with poor coal quality and reduces or eliminates the need to burn imported coal. Sulfur dioxide removal efficiency has been demonstrated in excess of 95 percent and up to 99 percent depending on the entering SO₂ loading. Also, unlike wFGD, CFB absorbers can be designed to remove 99 percent of the SO₃ because the lime reagent has a high affinity for SO₃.

There are lots of options and lots of site-specific conditions where the total cost of ownership will be different for the various technologies. McIlvaine conducted 9 hours of webinars for BHE to help them seek a NO_x upgrade solution. It turned out that ozone injection in the scrubber was the best option. Now this may also be the best choice for EU plants that need to reduce NO_x to meet the new BREF limits.

In a Modern Power Systems article last July, AECOM, ARVOS and Linde proposed a holistic approach to meeting the BREF emissions requirements, while maintaining efficiency, and attaining zero liquid discharge (ZLD). The concept consists of a combination of three technologies: LOTOX™ (low-oxidation-temperature, low-cost NO_x control using ozone injection); AdvX™ air preheater upgrade; and SBS Injection™ (to reduce SO₃ levels upstream of the air heater).This article was written by three individuals often cited in McIlvaine publications. Jonas Klingspor, ARVOS; Frank Fitch, Linde Group; and Blake Stapper, AECOM.

The system proposed here consists of an upgrade of the air preheater and control of the SO₃ concentration ahead of the preheater to minimal levels. Ozone is then injected upstream of the wet scrubber to oxidize the NO_xto a soluble state that is captured in the scrubber slurry. The excess heat created by the air preheater upgrade is then directed to a spray dryer where the scrubber wastewater is evaporated.

The preheater upgrade employs the new AdvX™ heat recovery technology from Ljungström (a division of ARVOS). This can extract a significant amount of additional energy from existing air preheaters. The additional energy can be used in several beneficial ways, including improving the boiler heat rate, evaporation of wastewater and stack gas reheat.

Critical to the success of the approach described in the article is the ability to reduce flue gas SO₃ levels to less than 10 mg/Nm³at the air preheater inlet. AECOM’s SBS Injection™ process is the only technology that can consistently achieve such levels. As a result, Ljungström has licensed it from AECOM for applications in Europe and in China.

By removing SO₃ and lowering the flue gas temperature, a number of additional environmental benefits may be realized. These include reductions in NO_x, PM, and Hg emissions, and a decrease in fresh water consumption and wastewater treatment demand. This solution also provides new operating flexibility for plants with SCR by making it possible to operate at low loads without any adverse impact on the catalyst. The SO₃ control system can, in addition, provide mercury oxidation using AECOM’s proprietary HBS Injection™ process which co-injects sodium bromide with the sodium carbonate solution.

There are a number of plants that were able to comply with the IED NO_x limits of 200 mg/Nm³ but are unable to achieve the BREF NO_x limits with their existing equipment. These plants would benefit from a polishing technology that can achieve the required NO_x reduction for a minimal capital expenditure. Linde’s LOTOX™ technology offers precisely that. Ozone is injected into the flue gas downstream of the air preheater to oxidize insoluble NO_x to higher oxides that are readily soluble for capture as nitrate in the slurry of a wet flue gas desulfurization system. The low temperature process (optimally ≤150°C) allows stable and constant control regardless of variation in load or NO_x concentration.

Andritz supplied dry scrubbers to the Chilean electricity generation company AES Gener S.A. and its subsidiary Norgener S.A. It supplied two turnkey flue gas desulfurization (FGD) plants, including two fabric filters, for the 280-MW Tocopilla coal-fired power plant owned by the Chilean electricity generation company AES Gener S.A. and its subsidiary Norgener S.A.

Andritz also supplied an FGD plant and a fabric filter for Unit 1 and a bag filter plant for the Ventanas coal-fired power station.

This contract generated over €100 million ($131.7 million) in revenue for Andrtiz. Both plants use the Andritz Energy and Environment (AE&E) TurboSorp dry desulfurization technology. The scope of supply included design, engineering, manufacture, installation, and startup of the plants on an EPC basis. The units have been operating since 2014.

Corporate Name: EVN	Unit Size: MW 660
Plant Name: Genco 3 Vinh Tan 2	Vĩnh Tân commune, Tuy Phong district, Bình Thuận province. Vietnam
Unit # 1	Specific product purchases 2019
Forecasts can be supplied for sixteen types of valves, four types of pumps, actuators, limestone, lime, precipitator internals, dust bags, gas instrumentation, liquid instrumentation, controls, treatment chemicals, ammonia, urea, catalyst, cartridges, dewatering filter belts, membrane modules, linings, nozzles, mist eliminators, fans, air compressors, oxidation compressors, motors, VFD, seals, packing, hose, couplings, compressed air filters, lubrication filters.	Ball Valves - $170,000
	Butterfly Valves - $120,000
	Globe Valves - $190,000
	Plug Valves - $100,000
	Gate Valves - $150,000