FABRIC
FILTER       
NEWSLETTER  

July 2019, No. 525

 

MARKETS

·         U.S. Coal Plant Environmental Upgrades to Cost More Than $50 Billion

·         Coal By-products Including Rare Earths Will Be A Game Changer

·         Join the Debate on Insitu Rare Earth Recovery

·         Combust Flow and Treat Market Research Options

BIOMASS

·         Andritz to Supply a Highly Efficient Fluidized Bed Boiler for a Biomass Power Plant in Japan

CEMENT

·         FLSmidth Wins Contract for New Cement Plant in Morocco

·         Technische Textilien Lörrach’s Latest Reference for the Dedusting of a Cement Plant

MANUFACTURING

·         Nederman Supplies Dust Collection System for Clayton Fixture Company

COMPANY NEWS

·         Siemens’ Gas and Power Continues Focus on Productivity and Competitiveness

·         AECOM to Spin off Management Services Segment

·         Porvair Filtration Group Expands in Southern and Eastern Europe 

REGULATIONS

·         Power Plant Emissions Down Substantially in U.S. Since 1990

·         EPA Finalizes Affordable Clean Energy Rule

·         Repeal of the Clean Power Plan and Emissions Guidelines for Greenhouse Gas Emissions from Existing Electric Utility Generating Units

·         ArcelorMittal Indiana Harbor Fined for Baghouse Exposure

MARKETS

U.S. Coal Plant Environmental Upgrades to Cost More Than $50 Billion

The 200,000 MW of remaining coal-fired capacity in the U.S. will require an investment of more than $50 billion to meet the solid waste, groundwater, wastewater and air emission limits. The McIlvaine tracking system has profiles of the utilities with summaries of the programs and also weekly reporting in the Utility E-Alert. Here is the profile summary for Vectren.

Vectren operates the Culley and Brown units comprising four coal-fired boilers. It will no longer operate the Warrick 4 plant for ALCOA.

It faces major expenditures to meet the CCR regulations. There is a big potential for pond dewatering and beneficiation of ponded flyash. Environmental improvements as outlined in the NPDES permit amended February 2018 specify that a dry bottom ash transport water system must be installed prior to December 2020, and the FGD waste water system must be upgraded to a chemical-precipitation biological system by February 2021 or a zero liquid discharge (“ZLD”) system by December 2023.

Vectren has been selling its dry flyash since 2009. Last year it started discussions with a potential partner to explore beneficiation of the ponded ash. In April 2019 the State of Indiana denied Vectren the permit to proceed with a large natural gas-fired power plant. It had planned to upgrade the Culley plant and retire the Brown plant because of the scrubber problems. Now it will have to consider extending the life of the Brown units.

The A.B. Brown 1 & 2 units use sodium carbonate double alkali scrubbers. High maintenance costs of these scrubber will probably now be addressed since the remaining life has now been extended.

Each Brown unit has a separate scrubber that was installed when the plants were built in 1979 and 1986. An independent consultant conducted a condition assessment of the Brown scrubbers and concluded the alkaline scrubbers have an expected life cycle of 16 years. They are now beyond that expected useful life. Given their current condition, the consultant recommended retirement of both scrubbers within the next 5-10 years. Brown Unit 1 will be 45 years old and Brown Unit 2 will be 38 years old in 2024. The recommended replacement is one forced oxidation scrubber to remove SO2 from both units. The estimated capital cost is nearly $340 million. Along with a new forced oxidation scrubber in order to comply with the Effluent Limitations Guidelines (ELG) rule, the new scrubber will require a wastewater treatment system.

AB Brown Unit 1 has experienced the effects of cycling first-hand as Solid Particle Erosion (SPE) damaged a turbine by-pass valve allowing foreign particles to enter the turbine causing a three month outage and a $3.8 million repair during the summer of 2016. The issue appears to have occurred in the main steam outlet header where scale appears to have flaked off the internal header due to multiple thermal transitions related to unit cycling. Turbine valves are now being inspected and changed out more frequently to prevent a similar occurrence.

A profile of Vectren has been posted to the Utility Tracking System under operator profiles. The range of environmental investment requirements are addressed but there are many pages devoted to the CCR program and challenges.

For more information on the tracking system click on 42EI Utility Tracking System.

Coal By-products Including Rare Earths Will Be A Game Changer

The UK is importing flyash due to the retirement of coal fired boilers. The U.S. is gambling millions on the belief that rare earths extracted from flyash will eliminate a national security problem. Ash stored in ponds in the U.S. and other countries has been viewed as a contamination source but is increasingly being viewed as an important resource.

Suppliers of combust, flow, and treat products and services should consider the combined markets of remediation of existing ash pond and creation of valuable by products. The U.S. is leading in site remediation efforts, but 90 percent of the potential is in other countries.

There are opportunities in revisions to air pollution control systems. There are new ways to move flyash from the dust collectors to storage and new storage designs which apply to all the world markets. These can include air slides such as made by FLSmidth or dense phase coal sludge pumps such as made by Putzmeister. There are new ways to process flyash and bottom ash. The market to harvest flyash from existing ponds and landfills will continue in countries where new flyash generation is shrinking. In fact the demand increases as the supply of new flyash decreases.

It is a very dynamic market. Some U.S. utilities took steps to bring their ponds into compliance with new CCR standards and then due to some groundwater contamination lawsuits now must consider pond excavation. 

McIlvaine is addressing all the opportunities in its market reports on Precipitators, Fabric Filters, FGD, Valves, Pumps, Treatment Chemicals and IIoT. The opportunities at specific plants are being pursued with weekly coverage in the Utility E-Alert. Analysis of individual utilities is provided in 42EI Utility Tracking System. A sample for Vectren is shown at http://www.mcilvainecompany.com/brochures/vectren/page1.htm.

McIlvaine believes there is a big potential for insitu rare earths feedstock and is making a special effort to analyze the process in Coal Fired Power Plant Decisions 44I Coal Fired Power Plant Decisions.

Join the Debate on Insitu Rare Earth Recovery

The McIlvaine Company believes insitu rare earth recovery from coal combustion will be much more economical than using flyash ponds and landfills as the source. The assertion is that coal-fired boilers can generate rare earth feedstocks, 30 percent hydrochloric acid, and contaminant free ash, while avoiding many of the present problems of not removing HCl separate from the SO2.

There is a substantial factual basis for the assertion based on the operation of some coal-fired plants and many municipal waste incinerators. Other than McIlvaine there is no other source who seems to have evaluated this opportunity. The University of Kentucky, Battelle, EPRI, Georgia Power, ACAA, Chinese researchers, suppliers of waste to energy systems with acid and metal by-product sales and others will have insights which would help determine the efficacy of this option.

The basic case is available for review at Insitu Rare Earth Recovery System. Input from any source will be welcomed and comments posted. Webinars to discuss this option will be held at the appropriate time. Bob McIlvaine welcomes questions or comments at 847-784-0013, cell 847-226-2391, email - rmcilvaine@mcilvainecompany.com.

Combust Flow and Treat Market Research Options

The need for market research ranges from an immediate answer to a question to a business program with forecasts for each major prospect. McIlvaine has been supplying research across this spectrum in the air, water and energy fields since 1974. Cost and timing as well as intended use, influence the market research purchase decision. Here are reasons McIlvaine should be your choice for the range of needs.

(1)  Need an answer today to a few questions: McIlvaine can supply any of our online market reports instantly and can provide a webinar to help answer specific questions. Here are details on each of the reports divided into air, water, energy, and contamination control categories. http://home.mcilvainecompany.com/index.php/markets

(2)  Need guidance today: Bob McIlvaine can provide a one-hour webinar with a number of participants. Focus can be on a particular prospect, product, industry, or location.   McIlvaine displays millions of pages of information online. The most appropriate information can be displayed to provide the guidance.

(3)  Need data to allocate sales promotion expenditures or to set quotas: McIlvaine has forecasts for each product in each industry in each country. Segmentation for each state in the U.S. and each province in China can also be supplied.

(4)  Need to value an acquisition target or make a new product investment decision: McIlvaine has been an advisor on many acquisitions and has done numerous studies to determine the potential markets for a new product. Clients have included the largest companies but also small ones. Since McIlvaine also has services on the end user industries it has the latest insights on fast developing opportunities such as hydraulic fracturing or single use biopharmaceuticals.

(5)  Build a business program around market research: Forecasts of purchases by each major prospect can be provided along with a program to reach the decision makers in a way which will maximize profits.

Bob McIlvaine can answer your questions at 847-784-0013 or rmcilvaine@mcilvainecompany.com.

BIOMASS

Andritz to Supply a Highly Efficient Fluidized Bed Boiler for a Biomass Power Plant in Japan

Andritz has received an order from Toyo Engineering Corp. (TOYO), Japan, to deliver a PowerFluid Circulating Fluidized Bed boiler with flue gas cleaning system for a new biomass power plant to be built in Ishikari city, Hokkaido, for Ishikari Shinko New Energy Hatsuden Godo Kaisha. Startup is scheduled in 2022. 

The PowerFluid boiler to be supplied by Andritz features lowest emissions, high efficiency and availability, and highest fuel flexibility. It forms an essential part of a high-efficiency biomass power plant for supply of green energy to the national grid. The biomass power plant fired with wood pellets as well as palm kernel shells will generate around 50 MWel of power.

This project is the fifth order in a row for supply of an ANDRITZ PowerFluid Circulating Fluidized Bed boiler for the Japanese market, thus demonstrating ANDRITZ’s extensive know-how and recognized expertise in the biomass power boiler sector.

CEMENT

FLSmidth Wins Contract for New Cement Plant in Morocco

FLSmidth has won a contract to deliver a greenfield cement plant to a new customer in Morocco. The contract is worth DKK 335 million.

FLSmidth together with Société Générale des Travaux du Maroc (SGTM) yesterday signed a contract with TEKCIM S.A. to co-deliver a full cement plant with a capacity of 3600 tonnes per day. The plant will be built in Ouled Ghanem in Morocco's El-Jadida province and is scheduled to be fully operational in the 3rd quarter of 2022. FLSmidth's share of the turnkey contract amounts to DKK 335 million.

This is the first business cooperation between FLSmidth and TEKCIM. The process leading to the agreement has involved the African Development Bank as well as local commercial banks, and the parties involved have set very high standards in terms of quality and sustainability.

"The project includes state-of-the-art equipment that will provide TEKCIM with a very efficient cement plant. It also demonstrates FLSmidth ability to support customers where financing is involved, which has been a key aspect to be awarded this project. 

The contract scope includes engineering, supply of a full range of equipment from crushing to packing and loadout, supervision, commissioning and training of a local workforce.

Technische Textilien Lörrach’s Latest Reference for the Dedusting of a Cement Plant

A filter medium made of meta-aramide and polyphenylene sulfide fibers is successfully being used in a dust collector in the cement industry. The warranty term of 24 months + 12 months pro rata was fulfilled, and the filter bags are still working to the satisfaction of the plant operator. In order to achieve and optimal dust collection, they selected fine fibers and adapted the grammage weight of the needlefelt to the dust load.

Example for the use of a needlefelt made of a MA+PPS blend, 600 g/m2, fine fiber

Gas volume (Bm3/h)                  123,000

Filtration surface (m2)                 1,937

Cleaning                                   compressed air

Raw gas dust load (g/Nm3)        420

Clean gas dust load (g/Nm3)        5

Temperature (°C)                       130/150°

 

MANUFACTURING

Nederman Supplies Dust Collection System for Clayton Fixture Company

Founded in 1963, Clayton Fixture Co. is a commercial fixture company that manufactures tabletop, cabinets and other related accessories commonly found in restaurants. Clayton Fixture Co. had a dust control problem that needed to be solved. Nederman provided a dust collection solution to address their specific manufacturing process needs. The installed high and low vacuum systems have substantially improved cleanliness of Clayton Fixture.

The high vacuum system is used for on-tool extraction during the sanding and routing process of the solid surface top fixtures. Installation included a complete configured NFKZ3000 5+1 dust collector sized for 30,000 CFM that included CARZ Valve, Abort Gate, Spark Detection System and Quick Fit Ductwork for the safe handling of combustible wood dust. Clayton Fixture Co. has improved shop efficiency and cleanliness with the Nederman system.

Nederman’s dust collectors address the issue of combustible dust. Processing of combustible raw material creates combustible dust. The dust has 1000 times or more larger surface, which results in a very quick combustion if ignited. This results in pressure increase and explosions in enclosed spaces.

Fine particles suspended in/mixed with air can be ignited when the concentration is above a threshold value. The value for many dust types is so high that normal view is obstructed, so this is normally not the main risk at workplaces. The main risk at workplaces is typically dust layers that become suspended in air by a sudden movement or cleaning with pressurized air.

Dusty processes are traditionally polishing, blasting, grinding, crushing, milling, transportation of granulates, etc. Dust is also created in many processes using high-speed tools to achieve very smooth surfaces such as sawing, grinding and cutting. Also, 3D-printing with powders generate dust that can be combustible.

Organic dust materials are explosive, such as wood, flour, sugar, grain and soybeans. Also, particles from pharmaceuticals and pesticides as well as rubber, textiles and plastics can be explosive. This even accounts for materials such as aluminum and iron that are not combustible in larger pieces but can be when in dust form.

COMPANY NEWS 

Siemens’ Gas and Power Continues Focus on Productivity and Competitiveness

Siemens recently informed its employee representatives about further planned measures for strengthening the productivity and competitiveness of Siemens' Gas and Power (GP) Operating Co. for the long term. "Our new Gas and Power Operating Co. setup has created synergies that better enable our company to deliver competitive performance in the midst of structural change in our industry. The planned measures will help us create more opportunity for growth and the security that comes from being a competitive player in the energy market," said Lisa Davis, member of the Managing Board of Siemens AG and CEO of Gas and Power.

Siemens announced that, against the backdrop of a challenging market environment, GP will — in addition to ongoing programs — require further savings of €500 million in order to significantly improve its cost competitiveness. The additional savings will be enabled by the new setup of the GP Operating Co. Merging and rightsizing the different businesses will save €200 million. A further €100 million will result from the new regional setup. And the remaining €200 million will be achieved by optimizing support functions.

The plans, as they have now been presented, call for reducing approximately 2700 jobs worldwide over the course of several years. Around 1400 of these jobs are in Germany. Siemens will now begin consultations with the relevant employee representatives and then implement the planned measures, including requalification programs in the wake of the structural transformation of the industry, in a way that is socially responsible. As Siemens also highlighted at its Capital Market Day, the growth-oriented Vision 2020+ strategy concept will also be reflected in workforce development. Taking into account the efficiency-related workforce adjustments across all areas, including today's adjustments at GP, there will, accordingly, be a net increase of around 10,000 jobs worldwide within the same time period.

Since last years' reconciliation of interests with employee representatives focused on the power generation business (Power and Gas), the new measures primarily address the EPC projects business as well as the power transmission products and systems business. For the EPC projects business, measures are required in order to reduce costs, adjust to the declining numbers of major projects and enable the business to be more selective in the market, finding the right balance between volume and margin. For the power transmission products business, the markets for transformers and switching technology are burdened by excess capacities, requiring measures for optimizing cost structures and capacities at all locations. Doing so will help preserve the competitiveness of these locations. In addition, across the GP Operating Company, bundling and optimization has reduced the need for some of the services provided by support functions.

AECOM to Spin off Management Services Segment

AECOM has unanimously approved a plan to pursue a spin-off of the company’s Management Services segment into a leading, standalone government services company. The transaction is currently expected to be completed in the second half of fiscal 2020.

As standalone entities, both AECOM and the government services business are expected to benefit from:

·         Strong management teams with a honed focus on their respective businesses and capital structures optimized to the unique characteristics of each business

·         Added long-term financial flexibility to invest in each business’s strategic growth priorities, and to allocate capital to the best and highest use

·         Separate boards of directors with skillsets and experience to provide focused insights and to support strategic and financial objectives and enhanced value creation

·         Company-specific incentive programs and performance indicators to most closely align employee incentive compensation opportunities with standalone business performance

·         Enhanced appeal to a broader set of investors suited to the particular strategic and financial characteristics of each business.

Porvair Filtration Group Expands in Southern and Eastern Europe

Porvair Filtration Group has announced the appointment of two new Business Development Managers in Europe.

In response to increased demand, Porvair’s New Milton Division has employed local experts to manage and support their sales channels, offering performance-driven filtration equipment for the process and industrial sectors.

Fabio Nicolodi, who has over 18 years’ experience in filtration, will drive growth by developing new and existing customers in Portugal, Spain, Italy, Greece and Malta.

Petr Straka, who has over 11 years’ experience, is responsible for developing new and existing customers in Poland, the Czech Republic, Bulgaria, Hungary, Romania and Slavic regions. Petr will also support Russia as opportunities develop.

Their appointments underlines Porvair's commitment to expanding its operations in Europe, and both will support customers in the following market sectors: Original Equipment Manufacturers (OEM), chemical process, printing, bioscience, polymer and food and beverage. 

REGULATIONS

Power Plant Emissions Down Substantially in U.S. Since 1990

Power plant SO2 and NOx emissions have decreased 92 percent and 84 percent, respectively, since Congress passed major amendments to the Clean Air Act in 1990. Meanwhile, mercury air emissions from power plants have decreased 90 percent since 2000, as federal limits on mercury and other hazardous air pollutants from coal-fired power plants went into effect in 2015.

The revelations are just a few of the findings from a report titled “Benchmarking Air Emissions of the 100 Largest Electric Power Producers in the United States,” which was authored by M.J. Bradley & Associates and released in June. The benchmarking analysis is a collaborative effort among Ceres; Bank of America; power producers Entergy and Exelon; and the Natural Resources Defense Council (NRDC). The latest analysis is the 15th such report released since 1997.

“As harmful emissions from the U.S. power sector continue to decline, it’s clear that policy solutions, market forces, company leadership, and stakeholder engagement are successfully driving the clean energy transition,” Starla Yeh, Director of the Policy Analysis Group of the Climate and Clean Energy program at NRDC, said in a news release accompanying the report.

Notably, there was one recent exception to the downward trend in emissions. Power sector releases of CO2 increased 1 percent between 2017 and 2018. “The sector must ensure it recovers the ground it lost in 2018 with consistent and steep reductions in climate and air pollution over the coming decades in order to do its part in meeting domestic and global decarbonization goals,” Yeh added. Still, CO2 emissions have decreased 25 percent since peaking in 2007, even as U.S. gross domestic product — a measure of the total value of goods produced and services provided in the country — grew more than 35 percent over the same period.

The report says electricity accounted for almost 40 percent of primary energy use in the U.S. in 2018, and its share of energy supply is expected to increase in the coming decades with the electrification of transportation and other end-uses.

“As the benchmark analysis continues to make clear, we must increase corporate ambition and find solutions to transform the power sector at a scope and scale that matches the climate crisis,” said Dan Bakal, Senior Director of Electric Power at Ceres — a nonprofit organization focused on sustainability.

Interestingly, there is wide variability in carbon emission rates among U.S. power producers. Five of the 20 largest generators emit more than 1,500 lbs. of CO2/MWh while five others emit less than 650 lbs. of CO2/MWh. With its large nuclear fleet, Exelon emitted the least — 107 lbs. of CO2/MWh (less than a quarter the amount of any other producer) — while, of the top 20 producers, Ameren was at the high end, emitting 1696 lbs. of CO2/MWh. 

“As the largest producer of zero-carbon energy in the United States, Exelon stands with the overwhelming majority of our customers who want cleaner air and affordable, reliable energy,” said Exelon Senior Vice President, Corporate Strategy and Chief Innovation and Sustainability Officer Chris Gould. “The valuable insights and analysis from this report will help us continue to drive the deep decarbonization necessary to address the climate crisis facing our customers and communities.”

EPA Finalizes Affordable Clean Energy Rule

The U.S. Environmental Protection Agency (EPA) issued the final Affordable Clean Energy (ACE) rule — replacing the prior administration’s Clean Power Plan (CPP) with a rule that restores the rule of law and empowers states to reduce emissions while providing affordable and reliable energy for all Americans.

These actions are the culmination of a review of the CPP, which was done in response to President Trump’s Executive Order 13873 - Promoting Energy Independence and Economic Growth. The actions also follow challenges from a large number of states, trade associations, rural electric co-ops, and labor unions who argued that the CPP exceeded EPA’s authority under the Clean Air Act, and an unprecedented stay of the CPP by the Supreme Court in 2016.

“We are delivering on one of President Trump’s core priorities: ensuring the American public has access to affordable, reliable energy in a manner that continues our nation’s environmental progress,” said EPA Administrator Andrew Wheeler. “Unlike the Clean Power Plan, ACE adheres to the Clean Air Act and gives states the regulatory certainty they need to continue to reduce emissions and provide a dependable, diverse supply of electricity that all Americans can afford. When ACE is fully implemented, we expect to see U.S. power sector CO2 emissions fall by as much as 35 percent below 2005 levels.”

The ACE rule establishes emissions guidelines for states to use when developing plans to limit carbon dioxide (CO2) at their coal-fired power plants. Specifically, ACE identifies heat rate improvements as the best system of emission reduction (BSER) for CO2 from coal-fired power plants, and these improvements can be made at individual facilities. States will have 3 years to submit plans, which is in line with other planning timelines under the Clean Air Act.

Also contained within the rule are new implementing regulations for ACE and future existing-source rules under Clean Air Act Section 111(d). These guidelines will inform states as they set unit-specific standards of performance. For example, states can take a particular source’s remaining useful life and other factors into account when establishing a standard of performance for that source.

ACE will reduce emissions of CO2, mercury, as well as precursors for pollutants like fine particulate matter and ground-level ozone: In 2030, the ACE rule is projected to:

·         Reduce CO2 emissions by 11 million short tons

·         Reduce NOx emissions by 7100 tons

·         Reduce PM2.5 emissions by 400 tons

·        Reduce mercury emissions by 59 pounds

·         Reduce SO2 emissions by 5700 tons

EPA projects that ACE will result in annual net benefits of $120 million to $730 million, including costs, domestic climate benefits, and health co-benefits.

With ACE, along with additional expected emissions reductions based on long-term industry trends, they expect to see CO2 emissions from the electric sector fall by as much as 35 percent below 2005 levels in 2030.

More information, including a pre-publication version of the Federal Register notice and fact sheets, are available at https://www.epa.gov/stationary-sources-air-pollution/affordable-clean-energy-rule.

Repeal of the Clean Power Plan and Emissions Guidelines for Greenhouse Gas Emissions from Existing Electric Utility Generating Units

EPA is finalizing three separate and distinct rulemakings. First, the EPA is repealing the Clean Power Plan (CPP) because the Agency has determined that the CPP exceeded the EPA's statutory authority under the Clean Air Act (CAA). Second, the EPA is finalizing the Affordable Clean Energy rule (ACE), consisting of Emission Guidelines for Greenhouse Gas (GHG) Emissions from Existing Electric Utility Generating Units (EGUs) under CAA section 111(d), that will inform states on the development, submittal, and implementation of state plans to establish performance standards for GHG emissions from certain fossil fuel-fired EGUs. In ACE, the Agency is finalizing its determination that heat rate improvement (HRI) is the best system of emission reduction (BSER) for reducing GHG — specifically carbon dioxide (CO2) — emissions from existing coal-fired EGUs. Third, the EPA is finalizing new regulations for the EPA and state implementation of ACE and any future emission guidelines issued under CAA Section 111(d).

Federal Register / Vol. 84, No. 130 / Monday, July 8, 2019 / Rules and Regulations

ArcelorMittal Indiana Harbor Fined for Baghouse Exposure

ArcelorMittal Indiana Harbor has been fined $10,000 by the Indiana Occupational Safety and Health Administration, after IOSHA found that an operator at the main stack baghouse was exposed to unacceptably high levels of both lead and cadmium dust.

Each violation will cost ArcelorMittal $5000 and must be abated by September 5, IOSHA said in an order issued on June 4.

According to IOSHA, in an inspection conducted on April 29, a baghouse operator was exposed to lead dust over an eight-hour period in an amount approximately 20 times higher than the permissible exposure limit. Type of violation: serious. Fine: $5000. 

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