FGD and DeNOx
NEWSLETTER

November 2019
No. 499

 

Table of Contents

 

 

MARKETS

 

INDUSTRY NEWS

 

 

CONTINUING OF IMPORTANT TOPICS AT POWER-GEN

 

 

 

MARKETS

 

FGD Market offers Billions of Dollars of Profits

 

More than $50 billion per year will be spent on the systems, parts, consumables and services by power companies to build and maintain flue gas desulfurization (FGD) systems. If these systems are not meeting SO2 emission limits the power plant must cease operations. All the elements of severe service are present: corrosion, temperature, and abrasion. As a result, power companies are focused on buying products with the lowest true cost. This translates into billions of dollars of potential profits for suppliers.

 

These profits are achievable by identifying the potential for each customer, providing evidence of the lowest true cost and then convincing the customer (validating the claims).

 

A cost-effective program is available. FGD Most Profitable Market Program costs less than $10,000 per year. It includes customized forecasts for each country and each purchaser for any one of the following.

 

Chemicals

Ball Mills

Instrumentation

Compressors

Lime

Scrubbers - Wet

CEMS

Valves

Pumps

Filters

Mist Eliminators

Scrubbers - Dry

Filter Belts

Nozzles

Stainless Alloys

Fans

Limestone

Remote Monitoring

Filter Bags

Controls

Pneumatic Conveying

 

 

This is an extension of http://home.mcilvainecompany.com/index.php/markets/air/n027-fgd-market-and-strategies.

 

Identification of each purchaser and weekly project tracking is included in http://home.mcilvainecompany.com/index.php/databases/42ei-utility-tracking-system.

 

The validation process with customers is accomplished through http://home.mcilvainecompany.com/index.php/silobusters/44i-coal-fired-power-plant-decisions.

 

This service allows the purchasers to conclude which products have the lowest true cost.  Here is a link to one of the recent webinars https://youtu.be/1GSbwSiTZrE.

 

The broader Most Profitable Market Program is detailed at www.mcilvainecompany.com.

 

Bob McIlvaine can answer your questions at rmcilvaine@mcilvainecompany.com; direct 847-784-0013 and cell 847=226=2391.

  

INDUSTRY NEWS

CCR/ELG Compliance Webinar

A free live webinar on the proposed CCR/ELG rules was undertaken December 3. by Burns & McDonnell‘s professionals who have hands-on experience with these projects. The three presenters, who together have executed CCR/ELG projects and/or studies for 126,000 megawatts across 300 units in the fleet, delved into what exactly has changed, outline your next steps for compliance and discussed real-world scenarios of how the new regulations would be applied to various facility types and retirement dates. The presenters were Jason Eichenberger, PE, CCR Disposal Specialist, Tisha Scroggin-Wicker, PE, Wastewater Treatment Specialist and Mike Roush, PE, CCR Handling Specialist.

 

Balkan Coal Plants Failing to Meet European Union Standards

 

The Energy Community (EC) has warned that all member countries that have coal plants in their energy mix do not comply with standards for at least one of nitrogen oxides, sulfur dioxide and dust emissions. Kosovo breached all three emission limits while Bosnia and Herzegovina and North Macedonia did not comply with sulfur dioxide and dust standards. Moldova did not report its annual emissions for 2018. The EC is an organization between the European Union and nine Southeast European countries seeking to establish a pan-European energy market. The EC’s Deputy Director, Dirk Buschle, warned that the there was a need to reform the EC treaty to improve its enforcement mechanism so that, for example, Bosnia and Herzegovina’s lack of compliance with the state aid rules in relation to the Tuzla 7 coal-fired power plant could be addressed.

 

Most Indian Coal Units Won’t Comply with Pollution Standards by 2022

 

An analysis of Central Electricity Authority (CEA) data reveals that over half of India’s 440 coal units will not comply with new pollution standards by early 2022, even though the Association of Power Producers (APP) argued that it would take between 27 and 30 months for flue gas desulfurization (FGD) units to be installed. FGD units dramatically reduce sulfur dioxide emissions. The Indian Government’s original deadline was for all coal plants to comply with the new pollution standards by December 2017 but, following lobbying by the APP, which represents companies including Adani Power, the deadline was extended until December 2022 with a staggered timetable for compliance. The CEA data indicates that 267 units, which have a combined capacity of 103,400 MW, are scheduled to comply with the standards by February 2022. However, the owners of 224 units, which have a capacity of 84,800 MW, have not yet ordered FGD units.

 

KEK to Get €76 Million Grant to Cut Pollution from Kosovo B Power Plant

 

Kosovo Energy Corp. (KEK) has announced Kosovo will receive a €76 million grant from the EU’s Instrument for Pre-accession Assistance (IPA) for a project to reduce air pollution from the Kosovo B coal-fired power plant.

 

The implementation of the project, which involves the replacement of the Kosovo B power plant’s electrostatic precipitator, is expected to start within six months.

 

After the completion of the project, the Kosovo B power plant will operate in line with EU standards by 2021, KEK said, adding that the EU office in Kosovo is in the final phase of project preparation. KEK also recalled that it has invested around €60 million in environmental protection projects in the past ten years.

 

As much as 98 percent of electricity generated in Kosovo comes from two old, inefficient and highly-polluting lignite-fired power plants, Kosovo A and Kosovo B. According to a World Bank report on Kosovo’s energy sector, citizens suffer power shortages due to insufficient output, aging grids, and electricity thefts, the media recalled.

 

The European Commission has also warned that Kosovo continues to rely on the highly-polluting lignite, even though some progress has been seen on renewables. In a report, the European Commission recommended, among others, that Kosovo should prepare for the decommissioning of the Kosovo A power plant and the environmental upgrade of Kosovo B.

 

According to earlier reports, the Kosovo government plans to build a new coal-fired power plant, in a project that is expected to cost more than €1 billion. The planned Kosova e Re power plant would have an installed capacity of 500 MW.

 

Thermax Q2 Order Booking Up 28%, Revenue Higher By 12.5%

 

For the 2nd quarter of Fiscal Year 2019-20, Thermax posted consolidated operating revenue of Rs. 1606 crore, up 12.5 percent as compared to Rs. 1428 crore in the corresponding quarter, last year.

 

Profit after tax (PAT) stood at Rs. 26 crore as compared to Rs. 75 crore (includes company's share of profit/loss in joint venture) in 2nd quarter.

 

As on September 30, 2019, Thermax Group had an order balance of Rs. 5334 crore (Rs. 6411 crore) down 16.8 percent. Order booking for the quarter, at the consolidated level, was at Rs. 1723 crore (Rs. 1344 crore), up 28.2 percent. The Environment segment of the company has bagged Rs. 471 crore Flue Gas Desulfurization (FGD) order during the quarter.

 

On a standalone basis, from continuing operations, Thermax posted an operating revenue of Rs. 838 crore for the quarter, compared to Rs.758 crore in the corresponding quarter of the previous year. PAT for the quarter remained the same as last year's Rs. 39 crore.

 

Carper and Alexander Defend Mercury Rule

 

U.S. Senators Tom Carper (D-DE), top Democrat on the Environment and Public Works Committee and Lamar Alexander (R-TN), chairman of the Energy and Water Development Appropriations Subcommittee, penned an op-ed published in USA Today defending the Mercury and Air Toxics Standards (MATS), protections that have cost-effectively reduced toxic air emissions from power plants since 2012. In the op-ed, Senators Carper and Alexander urge the Environmental Protection Agency (EPA) to reverse course on their December 2018 proposal undoing the mercury rule, writing that it has improved public health and supported economic growth in Delaware, Tennessee and throughout the country.

 

“The mercury rule, which limits mercury emissions from coal- and oil-fired power plants, has resulted in 90% less mercury in the air than a decade ago. But now, the Environmental Protection Agency is moving forward with a proposal that asserts it is no longer ‘appropriate and necessary’ to protect the public from our country’s largest sources of mercury and air toxic emissions,” the senators wrote.

 

The senators continued, “Changing the rule after billions of dollars have already been spent means that utilities will have less certainty about federal regulations, and it will be more difficult to maintain steady electricity prices for American families in the future. The gains we have made over the past decade to protect children and families from dangerous mercury pollution should not be lost.”

 

ADES Profits from Refined Coal

 

L. Heath Sampson, President and CEO of ADES commented, "During the 3rd quarter Tinuum was able to identify and secure tax-equity investors for two additional refined coal facilities. The incremental tonnage contracted by these two transactions brings our year-to-date total to roughly 15 million tons, comfortably exceeding our previous guidance of 12 million. We've been very pleased with this progress; however, coal-dispatch pressure and utility closures have impacted our total expected RC cash flows. We have updated these RC cash flows and they will continue to support our capital allocation priorities and our organic investment in our activated carbon growth channels. Additionally, we are now more optimistic related to Tinuum's ability to obtain incremental cash flows through additional RC facility closures."

 

Highlights

 

Recognized consolidated revenues of $19.1 million compared to $5.1 million in the 3rd quarter of 2018.

 

Fuel Tech Awarded Air Pollution Control Orders Totaling $2.1 Million

 

Fuel Tech, Inc. announced the receipt of multiple air pollution control (APC) contracts from customers in the US and Europe. These awards have an aggregate value of approximately $2.1 million.

 

An order was received for a Selective Catalytic Reduction (SCR) system for an industrial process unit firing natural gas located in the United States. The scope includes Fuel Tech’s SCR and UDI™ Urea Direct Injection technologies, along with ancillary systems to reduce nitrogen oxide (NOx) emissions from a metal processing line. Fuel Tech’s UDI process, similar to their ULTRA® technology, provides the safe use of urea reagent where SCR is used to reduce NOx, eliminating the hazards associated with the transport, storage and handling of anhydrous or aqueous ammonia. Equipment deliveries are expected to be completed in the third quarter of 2020.

 

A contract was received for an ULTRA® system that will be installed on a natural gas-fired steam boiler in the western United States retrofitted with SCR technology. This ULTRA system is a permanent system on a unit where a temporary ULTRA rental unit replaced a competing technology. Equipment delivery will be in the first quarter of 2020.

 

In Europe, several change orders to three existing contracts for SCR related systems were also received. Work will be completed in the fourth quarter of 2019.

 

B&W Generated Consolidated Adjusted EBITDA of $10.1 Million in the Third Quarter

 

Babcock & Wilcox Enterprises, Inc. ("B&W Enterprises") announced 3rd quarter 2019 GAAP loss from continuing operations improved by $47.2 million to a loss of $57.0 million compared to a loss of $104.1 million in 3rd quarter 2018. Adjusted EBITDA also improved by $36.8 million to a positive $10.1 million compared to negative $26.7 million in the prior year period, resulting in the company's second consecutive quarter of profitability in 2019 on an adjusted EBITDA basis.

 

"Our performance in the 3rd quarter of 2019 builds on last quarter's improvements following our improved operational performance and cost-saving efforts. Our consolidated business continued to show increasing operating margins and for the second consecutive quarter the company was profitable on an adjusted EBITDA basis. Our Babcock & Wilcox segment continued its solid performance and across the company we are showing steady progress on our strategy to improve profitability by focusing on our core strengths and reducing unnecessary G&A," said Kenneth Young, B&W Enterprises Chief Executive Officer. "With our equitization transactions completed in July, we are working to re-finance our existing credit facility to support our growth. As 2019 draws to a close, we are demonstrating the underlying core value of our businesses to our customers and shareholders and laying the foundation to leverage new opportunities on a worldwide basis."

 

"We're continuing to implement our cost-savings initiatives, for $119 million in annualized savings," said Lou Salamone, B&W Enterprises Chief Financial Officer. "Approximately $106 million of these initiatives have now been implemented and we are aggressively looking for further ways to streamline our operations while maintaining our focus on our customers and quality. As we turn toward 2020, we expect to see improvement each quarter as our cost-savings measures continue to translate to bottom-line results. We are also seeing our new opportunity pipeline increase for our core technologies across the Babcock & Wilcox, Vølund and SPIG segments globally.

 

The company's focus on core technologies and profitability, as well as completion of the EPC loss contracts, were the primary drivers, as expected, of a decline in revenue compared to the 3rd quarter of 2018. Consolidated revenues in 3rd quarter 2019 were $198.6 million, down 33 percent compared to 3rd quarter 2018. The sales of Palm Beach Resource Recovery Corp. ("PBRRC") in the 3rd quarter of 2018 and Loibl, a materials handling business in Germany in the 2nd quarter of 2019; and a lower level of activity on SPIG legacy loss contracts and lower volume of new build cooling system services in the SPIG segment following a change in strategy to improve profitability, also drove the decline in revenue.

 

Babcock & Wilcox segment revenues decreased 15.3 percent to $161.8 million in the 3rd quarter of 2019 compared to $191.1 million in the prior-year period, primarily attributable to lower volume related to the periodic nature of large construction new build projects.

 

SPIG segment revenues decreased 70.4 percent as expected to $10.3 million in the 3rd quarter of 2019 compared to $34.8 million in 3rd quarter 2018, mainly due to a lower volume of new build cooling system projects as anticipated following the change in strategy to more selectively bid and focus on core geographies and products to improve profitability.

 

Vølund & Other Renewable segment revenues were $32.4 million for the 3rd quarter of 2019, compared to $76.5 million in 3rd quarter 2018. As expected, 3rd quarter revenues were lower compared to the prior year quarter due to the completion of the EPC loss contracts; the sales of PBRRC and Loibl, which had previously generated annual revenues of approximately $60 million and $30 million, respectively; and a shift to a core technology business model, partially offset by the startup of two operations and maintenance contracts in the U.K.

 

Hamon Displayed a Range of Equipment and Services at Power-Gen

 

Hamon provides a full range of aftermarket services for existing particulate control, emission control, cooling systems, heat recovery systems, and chimneys. It specializes in developing cost-effective solutions to the operational challenges of installed equipment regardless of original manufacturer

 

Hamon is a major supplier of both wet and dry cooling towers. Hamon has been awarded the order for the natural draft cooling tower for the Nizhnekamsk power plant. The Nizhnekamsk project is a new combined cycle power plant of 495 MW located in Tatarstan, Russia.

 

Hamon launched a new Standardized and Modularized Fabric Filters concept:  Plug & Play Fabric Filters have been developed and tested to meet the needs of the industry, worldwide and at a very competitive price. The following people will be at the Hamon stand and can be contacted in advance to arrange meetings. 

 

Hamon Custodis & R-C Cooling – John Boone, President – john.boone@hamon.com 908-333-2026.

 

Hamon Deltak – Ron Meyer – rmeyer@hamon.com – 763-557-7457.

 

Hamon Research-Cottrell – Neil Dahlberg - neil.dahlberg@hamn.com 617-510-1274 and Buzz Reynolds buzz.reynolds@hamon.com  908-578-0693.

 

CECO Displayed NOx Control Systems, Precipitator Controls and Dampers at Power-Gen

 

The company was an exhibitor at Power-Gen. It has a Record Backlog of $237.8 million, compared with $182.1 million as of December 31, 2018 and says that the energy sector has been strong.

 

CECO's Chief Executive Officer Dennis Sadlowski commented, "I am very pleased with our team's execution during the quarter which generated triple digit bookings, strong profitability and a record backlog for the company. Our investments are continuing to pay off as we realized sequential quarterly growth in all our key financial metrics. Our strong third quarter bookings, led by our Energy Segment, and our record backlog are the best predictors of the future, signaling improving revenue going forward."

 

The company supplies SNCR and SCR systems and a range of diverter, guillotine and diverter dampers for both coal and gas applications.

 

To arrange a meeting at the stand on dampers you can contact Jeff Korth | Vice President of Sales Effox-Flextor C: +1.513.295.5493| JKorth@OneCECO.com .

 

Improving Limestone Scrubber Efficiency

 

U.S. and Indian FGD operators both are interested in higher SO2 removal efficiency. In the case of U.S. operators faced with operating higher cost old plants, the potential to cut pump-connected horsepower is appealing. For Indian operators there is the potential to reduce capital as well as operating costs. Three options involve scrubber design. scrubber chemicals, and optimization systems.

 

Relative to scrubber design there are the following choices:

 

Another alternative is to use dibasic acid or another chemical to enhance scrubber efficiency.  Some plants in Europe add lime during periods when higher efficiency is needed.

 

India is moving forward with approximately 100,000 MW of FGD systems. This will require 15-20  million of tons of limestone per year. SHI-FW has conducted a study which shows that because of the poor limestone a CFB scrubber is the best choice for many plants.

 

https://www.shi-fw.com/wp-content/uploads/2019/10/Show-me-the-money-SHI-FW-CFB-Boiler-Economics-Modern-Power-Systems.pdf

 

This analysis  is based on a 300-MW plant with 0.6 percent sulfur. Limestone cost is 7 rs Crore /yr. ($989,000) based on 5 tons per hour and a cost of limestone at  1750 rs./ton ($ 24.50/ton) vs EPA cost estimates based on $30/ton. The tons/MW = 134.7.

 

Scrubber additives can improve the economics when using a poor-quality limestone. One answer is that if treatment chemicals can be justified for a 0.6% sulfur coal, they will be even more attractive for higher sulfur coals.

 

Here is the CEA specification for Indian Limestone.

 

cid:image001.png@01D58BC9.4FC29FE0

 

 

 

 Brad Buecker of Chemtreat has reviewed this analysis and concludes, “With regard to the analysis, the CaO range equates to a calcium carbonate (CaCO3) range of 82 to 91 percent. A quick thought suggests that this might be an excellent application for ChemTreat’s DBA replacement product. A general rule-of-thumb that I always followed is that limestones with 94 percent or greater CaCO3 concentration are usually quite reactive (if ground properly). My gut feeling says that the stones outlined in the analysis could be significantly enhanced in reactivity using our FGD1105 product.”

 

Brad wrote an article in Power Engineering earlier this month where he provided further details:

 

“Many plants do not have access to such high-purity limestones. The stone may contain a significant concentration of dolomite (MgCO3∙CaCO3) or inert materials that inhibit reactivity. Thus, supplemental methods are needed to boost the reactions. A common method that has been used for years is addition of dibasic acid (DBA) to scrubber process streams, but new technology is improving upon this chemistry. Dibasic acid is a generic name for a blend of relatively short-chain dicarboxylic acids (two COOH functional groups), which add hydrogen ions (H+) to help in the dissociation of limestone, and then circulates through the process to continue assisting with SO2-absorption chemistry. However, the availability, cost, and even efficiency of DBA has placed limits on the chemical’s effectiveness. An alternative is available that is much more promising for wet FGD reactivity enhancement.”

 

Personnel at the Longview Power Plant in Maidsville, WV had faced constant problems with handling and feeding DBA to the wet-limestone scrubber of their 770-MW supercritical steam generator. For example, the product must be kept warm to prevent solidification. Exacerbating the issues were DBA delivery constraints, both from a distance perspective and that the tank volume had to be lowered to less than 10 percent before introduction of a fresh load. Combined, these factors affected scrubbing efficiency and SO2 removal, the latter of which is a critical aspect of scrubber operation. Violation of discharge permits can result in load restrictions or forced shutdowns.

 

Accordingly, the plant staff began full-scale testing and then subsequent application of an alternative, specially-formulated organic acid blend with the product name of FGD1105 (patent pending). Almost immediately upon chemical addition, SO2 emissions dropped by approximately 35 percent to 40 percent, such that even at full load one of the scrubber’s five recycle pumps could be, and was, removed from service. Stack SO2 emissions only slightly increased from 120 lb/hr to 200 lb/hr following the pump reduction. This action alone reduced auxiliary power consumption by 3 MW, at a projected annual benefit of approximately $700,000. As a test, the plant staff removed a second recycle pump from service and found that SO2 removal was still more efficient than in the period prior to the FGD1105 addition. According to Chad Hufnagel, Longview’s Plant Manager, the ability to operate with 3 recycle pumps instead of 4 or 5 has provided additionally flexibility for recycle pump maintenance strategy, as well as offering additional net revenue opportunity with improved unit efficiency.

 

https://www.power-eng.com/2019/02/08/coal-fired-power-m-o-enhancing-wet-limestone-scrubber-efficiency/

 

Therefore, the cost saving is more than $700,000/yr. less the cost of the additive. There are other questions to pursue such as changes to wastewater treatment costs. This analysis is based on a spray tower. If a tray tower or rod deck scrubber is used, then the saving would have to be in fan rather than pump horsepower. Another question to be answered is the parasitic cost of power for the average Indian plant versus that in the U.S.

 

The McIlvaine Coal Fired Power Plant Decisions has a number of relevant papers. They include  INVISTA DBA Dibasic Acid - The McIlvaine Company.

 

www.mcilvainecompany.com/Decision_Tree/subscriber/Tree/DescriptionTextLinks/Richard...

 

There are a number of suppliers of DBA around the world. They include:

 

FGD Scrubber Monitoring and Control:  The use of the right chemicals is only part of the true cost reduction. Monitoring and control of parameters is equally important. The CEMS system should be used for process monitoring. In the case above the system could operate with 3, 4 or 5 pumps depending on the reactivity of the limestone. However varying sulfur levels in the incoming coal provide another variable. If SO2 is measured prior to the scrubber as well as at the stack the right balance between efficiency and energy consumption can be determined.

 

The measurement of liquids is also important. Brad Buecker addressed this subject in an older Power Engineering article. He pointed out that it is important to constantly measure the alkalinity in the scrubber module or modules, as too much alkalinity will waste reagent while lean alkalinity will impair SO2 removal. The technique universally employed in wet scrubbers is pH monitoring. These measurements must be continuous, with control of reagent feed rates based upon the readings. For the lab staff, grab-sample pH analyses are very important to make sure that the in-line probes/monitors are accurate.

 

The slurry circulating pumps can only handle so much mass before electrical requirements are exceeded. Like pH, scrubbers are equipped with continuous density monitors, typically utilizing radioactive detectors. Again, the lab staff needs to monitor density on a grab sample basis to ensure the accuracy of the continuous instruments.

 

Control of solids chemistry offers interesting challenges and is extremely critical to operation. Experience has shown that operation in either a completely oxidized state (no calcium sulfite-sulfate hemihydrate in the scrubbing slurry) or a completely un-oxidized state (no gypsum in the slurry) minimizes scaling in the scrubber. Scale buildups can be extremely problematic, as deposit formation on scrubber internals and subsequent gas flow restrictions may cause unit de-rates and even forced outages if gas flow is severely restricted.

The technique that has proven itself very well for scrubber solids analysis is thermogravimetry. A thermogravimetric analyzer (TGA) is a quantitative not a qualitative instrument, so the operator needs to have a good idea of the primary constituents in the sample before analysis. If the sample compounds decompose at distinct and separate temperatures, it becomes easy to calculate the concentration of the original materials. Wet-limestone scrubber byproducts lend themselves well to this technique.

 

https://www.power-eng.com/2008/07/01/properly-monitor-your-scrubber-chemistry/

 

The plant can vary the number of pumps in operation. An optimization system enables the plant to use the minimum number of pumps required to keep the outlet SO2 lower than limits. This also reduces the amount of limestone slurry required, but the major contributor to cost savings is cutting energy use by removing one or more recirculation pumps from service based on the input SO2 value. One optimization system available was described by Toshihiko Fujii of Yokogawa Electric Corp. in a recent Power Magazine article.

  Fig 1_Flue Gas Desulfurization flow diagram

 

 

 

FGD control is normally implemented by the distributed control system through the regulation of limestone slurry flow. The limestone slurry flow is controlled based on the pH value as measured by an analyzer installed in the absorber. Typically, the pH value must be controlled to ensure proper performance of the desulfurization process in the absorber, therefore the limestone slurry flow is controlled to maintain the proper pH value. For this control scheme, other indices such as the FGD inlet and outlet SO2 are not used, and all recirculation pumps are operated regardless of the inlet SO2 value, with slurry flow regulated by the control valve.

 

The optimization system typically consists of three functions: enhanced regulatory control, model-based prediction, and process value prediction. The system uses these three functions to continuously determine the minimum required number of recirculation pumps in operation, and to calculate the setpoint for the limestone slurry flow PID (proportional-integral-derivative) control loop.

 

A 700-MW coal-fired power plant in Japan implemented the optimization system. This plant runs about 300 days per year at baseload and is not in operation for the other 65 days of the year. The energy savings realized by running only the required number of recirculation pumps was 12.4 percent of the unit’s total house load, equating to about $900,000 in energy savings per year based on market conditions in Japan. Another benefit was reduced pump run times, which resulted in lower pump maintenance costs and extended pump life. A third benefit was less limestone usage.

 

https://www.powermag.com/advanced-process-control-for-optimizing-flue-gas-desulfurization/?pagenum=1

 

Libra Provides Ceramic Pumps and Impellers

 

Libra Fluid Equipment Co., Ltd. was founded in 1999 and provides pumps and parts  for various industries, such as mining, metallurgy, coal, power, petroleum, chemical, municipal, environmental, etc.

 

As a China-based slurry pump impeller manufacturer, Libra provides a broad range of impellers, including froth pump impeller, medium/light duty pump impeller, sump pump impeller, sand pump impeller and FGD (flue gas desulfurization) pump impeller or customized impellers. It produces its own pump impellers, and also can provide impellers for competitor pumps Libra Fluid does not represent or is not in any way affiliated with original pump manufacturers. As for the slurry pumps, Libra endeavors to “only supply parts to the aftermarket where components were originally designed and developed over twenty years ago (which other OEM’s have well and truly enjoyed returns to justify the initial product development – the reason patents expire after 20 years!).

 

Our aim is to provide end users an alternative supplier and so bring competition back into the pump aftermarket resulting in end users paying fair prices, obtaining realistic lead times, having better product support, and encouraging future product improvements by all OEM’s. All companies and end users benefit from competition.”

 

Duechting Ceramic Pumps demonstrate Lowest Cost of Ownership in U.S. Cement Plant

 

Due to its significant corrosive and abrasive characteristics, gypsum slurry is a very difficult medium to handle. An American cement plant with a yearly capacity of about 2 million metric tons has found a good solution for that issue when it installed the first of two scrubber systems in 1998. This application has similar wear characteristics to FGD.

 

The housings of the eight pumps in the limestone slurry cycle are not made from metal materials, but from a special material that was designed specifically for extremely harsh conditions. This material is a mixture of silicon carbide (SiC) and epoxy resin that is poured into precision molds and heat cured to form the pump components. The material must be machined with diamond tools due to it exhibiting a hardness close to that of diamonds. The material is completely impervious to corrosion and exhibits extreme abrasion resistance given its metallic-free composition and high hardness value.

 

The scrubber recycle pumps in this plant have operated at a flow rate of 1,310 cubic meters per hour (m3/h), 21.1 meters (m) of head and 630 revolutions per minute (rpm) for nearly 20 years, requiring minimum attention and service. Of course, the mechanical seals were exchanged from time to time. Apart from that, four impellers, one casing cover and some minor components were replaced. An additional 24 pumps are installed in the second scrubber system and other applications in the plant.

 

https://www.pumpsandsystems.com/pump-materials-wet-flue-gas-desulfurization

 

Sunbo Supplies FGD Pumps and Parts from Chinese Factory

 

Sunbo Pump supplies slurry pumps and replacement parts for Warman pumps. It supplies replacement slurry pump parts in High chrome alloy, rubber eElastomer) and Polyurethane, e.g., R55,S42 (Neoprene), U01 (Polyurethane), S12 (Butadiene), S21 (Butyl), SO2 (EPDM), SO2 (Haipalun gum), and special materials. Sunbo is headquartered in Shijiazhuang, China. It develops, manufactures and globally markets slurry pumps for delivering aggressive, abrasive, thick, or solid-filled slurries. 

 

http://www.sunbopump.com/pic/Desulphurization-Pump-in-China-Power-Plant-600TL-FGD-Pump.jpg

 

Hanhe is a Chinese FGD Pump and Parts Supplier with exports to India

 

Hanhe Pump Co., Limited is a slurry and dredging pump manufacturer and exporter. With more than 15-year development it has slurry pump design, production, on-site installation, technical support and approved by ISO9001:2008 certificate. It supplies slurry pump for Weir Pumps but is not associated with Trillium. It is located in Shijiazhuang City, China. It has offices in India at Hanhe Slurry Pumps Solutions D, Maharashtra, India.

 

 

CONTINUING OF IMPORTANT TOPICS AT POWER-GEN

 

Speakers and exhibitors contributed to the knowledge regarding flow and treat subjects at Power-Gen. It was part of an initiative explained at http://www.mcilvainecompany.com/PowerGen_2019/MPM/powergen_and_the_most_profitable.htm.

 

There were background documents to enhance discussion. They included:

 

Electrostatic Precipitator Power Supplies True Cost Investigation

 

Gas Turbine Inlet Filter True Cost Investigation

 

Turbine Bypass Valve True Cost Investigation

 

Dry Scrubbing True Cost Investigation

 

CCR True Cost Investigation

 

FGD Recycle Pumps

 

Improving Limestone Scrubber Efficiency

 

As part of the CCR investigation, a group, including SEFA, Charah, KraftPowercon and Burns & McDonnell personnel, met at the Burns & McDonnell stand to discuss the latest CCR developments and reflect on the speech given by Rob Erwin of SEFA. Tricia Scroggin of Burns & McDonnell provided some insights and invited  everyone to a free webinar on the subject. (see below).

 

EPA is proposing amendments to the closure regulations for the disposal of coal combustion residuals in response to the court decisions. In particular, the proposal includes:

 

 

These proposed rule changes provide  an example of the need for continuous discussion of the issues. The CCR  True Cost Investigation will continue to be expanded as will the other investigations.  Lots of information on turbine bypass valves was supplied by exhibitors ( see below) . DHA provided new insights on gas turbine inlet filter media. This data will be added and can be viewed at 

http://www.mcilvainecompany.com/PowerGen_2019/MPM/powergen_and_the_most_profitable.htm.

 

KSB is a Service Partner for the Entire Product Life Cycle

 

KSBServ companies in North America offer comprehensive services to help relieve the pressure and reduce the life cycle cost of challenging pump problems. KSBServ brings knowledge and creative solutions to improve the equipment reliability and system performance.

 

Services include:

 

Benefits include:

 

Solutions for obsolete equipment

Quick response time

Improved reliability of your pump and parts

Added longevity and cost savings.

 

A new, dedicated KSBServ in facility and training center in Port Arthur, TX is scheduled to break ground in 2020. This KSBServ center will offer the only service and training and certification program for LUV pumps in North America.

 

Benefits of Advanced Rubber Joint Arrangements

 

Lloyd Aanonsen, President of General Rubber Corp. was interviewed at his Power-Gen stand relative to expansion joints. He advises that “when concerned about the load carrying capabilities of any essential equipment and/or support structures, an optimal solution is neither to increase rigidity into the piping system or ignore the imposing pressure thrust forces as an effect of some expansion joint arrangements; but rather to incorporate more advanced rubber expansion joint arrangements that can facilitate both system flexibility and restraint when needed. This approach is also very much in line with owners and stress engineers who desire piping systems with smaller footprints, lower construction costs, improved energy efficiency, modular construction and less structural support.”

 

 

FGD and DeNOx Newsletter No. 499