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Fabric Filter Market for Coal Fired Electric Generators is Growing Faster than the Industry

Coal-fired power plants around the world will increase expenditures for fabric filter systems, bags and third party maintenance services by more than seven percent per year. The total market will be $3 billion by 2020.

Fabric Filter Market 2020 - $ millions
	Dry Scrubber	Particulate Only	Total
Hardware and Construction	400	600	1000
Bags, Cages, other Repair Parts	250	400	650
IIoT and Remote O&M Potential	500	800	1300
Total – Advise, Design, Supply, Construct, Guide, Maintain	1150	1800	2950

There are a number of positive and negative impacts on future fabric filter related sales to coal fired generators around the world.

• The coal-fired boiler capacity in Europe and the U.S. will shrink but will be more than offset by new Asian capacity.

• New plants will continue to select precipitators for more new capacity than will choose fabric filters. However the share for fabric filters will slowly increase.

• Some existing plants with precipitators which are not meeting emission limits are installing bags within the existing precipitator shell.

• Dry scrubbing and Dry Sorbent Injection (DSI) are gaining market share although wet limestone FGD is still the dominant choice.

• Catalytic ceramic filters are not expected to gain much penetration by 2020 but will potentially be the first choice for power plants in later years.

•New technical developments are shaping the forecast and create substantial unknowns.

Fabric filters can produce consistently low particulate emission rates. They are not impacted by changes in the coal. Electrostatic precipitator performance is affected by coal variations. Where mercury regulations are stringent activated carbon injected ahead of the fabric filter can result in higher removal rates than injection ahead of a precipitator.

Dry scrubbing involves less capital expense than limestone wet scrubbing. Direct sorbent injection has very low capital expense other than the fabric filter. However, reagent costs are high. Where stringent regulations are forcing scrubber additions but boiler life is limited, dry methods are more cost effective.

The fabric filter cake provides final absorption in dry scrubbing and DSI systems. Presently the cleaning of filter bags is done to optimize particulate removal. There is significant potential to optimize acid gas removal as well as particulate with new cleaning technology. Ceramic filters with embedded catalyst in conjunction with DSI are the lowest cost approach to remove particulate, NOx and acid gas. This is because only one vessel instead of three are needed. The approach has worked well with three meter bags on applications with relatively low air volumes. Longer bags are now being commercialized. This could lead to widespread use by coal fired electric generators.

All the existing and proposed fabric filter installations on coal- fired .boilers are tracked in 42EI Utility Tracking System.

Industrial Ventilation and Dust Collection Should Not Be Two Different Silos

Carefully engineered ductwork systems for frac sand plants (outdoors) have the same needs for optimum hood designs and balanced flow ductwork (without dampers) as industrial ventilation systems in foundries (indoors). Both have the same stringent regulations regarding silica dust. Industrial ventilation covers many types of air flow other than those ducted to a dust collector. On the other hand the ventilation design used at the pickup points in a dust collector system has a direct effect on the system cost and energy consumption.

A well-designed hood utilizes only as much capture air as is needed. The cost of the dust collector is a function of flow. So a hood that requires twice as much capture air results in twice the system cost. A balanced ductwork system maintains the best velocity. It is not so high as to cause abrasion and excess energy consumption. It has to be high enough to insure that material does not deposit in the ductwork. Dampers need to be avoided because they cause turbulence and plugging. A correctly designed system uses tapered ducting and a constant duct velocity throughout the system. Also turbulence is avoided with gradual rather than abrupt changes in direction.

The concern for worker exposure to particulates is primarily focused on individuals working in environments such as foundries and coal mines where silica dust is generated. However, the concern for workers is just as great in frac sand plants and facilities which create toxic metal dust. John Brown of IAC-Intl in a recorded presentation linked from the McIlvaine Global Decisions Orchard reviews the needs and solutions for frac sand plants. He also references both primary and secondary lead plants where fine particulate emission limits are much lower than they are for silica.

There are a number of companies who are eliminating the two silos. CECO has acquired Kirk & Blum, a major ventilation contractor. It also acquired Flex-Kleen and other companies making air pollution control equipment. Nederman purchased MikroPul to complement its ventilation activities. In April 2018 it purchased Auburn FilterSense which makes triboelectric dust monitors commonly described as broken bag detectors. This gives Nederman a tool by which to remotely monitor the system operation and schedule bag replacement as needed for environmental and other reasons.

3M has introduced a blue tooth enabled pressure sensor which is inexpensive enough than it can be placed on every furnace filter. This technology has even more justification for use in industrial ventilation systems. Those systems dealing with toxic dusts have even more justification to install continuous monitoring devices.

Companies such as IAC-Intl, Nederman and CECO have the opportunity to be involved with industrial ventilation and dust control from the design and construction through the entire life of the system. New analyzers, data analytics and process management software make remote monitoring and O&M support very valuable. The biggest profit potential is total solutions. The supplier can provide a fixed price for O&M and replacement parts. With skilled remote operators, the cost to the owner can be less than if the O&M is handled in-house.

Dry Scrubber Design-Construct-Guide-Maintain Market to Reach 9.6 Billion Dollars in 2020

Traditionally wet scrubbers have been used for removing SO2, HCl and other acid gases. But recently owners have favored the newer dry scrubbing technologies. The capital cost is much lower and there is no wastewater disposal problem. The disadvantage is the higher use of reagents. However with new monitoring and data analytics tools the reagent use can be optimized and the total cost of acid gas capture reduced.

The big beneficiaries are the lime and other reagent suppliers. Their revenues will reach $6.4 billion in 2010.

	Coal Fired Power $ mil	Waste Combustion $ mil	Kilns and Furnaces, Misc.- $ mil
Hardware And Construction	300	350	420
Consumables And Repair Parts	200	280	320
Lime, Sodium, Trona	1600	2100	2700
IIoT And Remote O&M Potential	360	460	500
Total -Design-Construct-Guide-Maintain	2460	3190	3940
Total	9590

The total design-construct-guide-maintain market will exceed $9 billion in 2020. The largest purchase will be the reagent. Increasingly process management software, wireless transmitters and data analytic will be utilized to most efficiently operate these systems. Some combination of SO2, HCl, SO3 and mercury often needs to be reduced. Multiple reagents, e.g., lime and activated carbon may be needed.

There are a range of dry scrubbing technologies being utilized. Dry sorbent injection is the least capital intensive. Other technologies utilize vessels. One vessel type is the spray drier, another is a fluidized bed. A third design utilizes concurrent flow and recirculation of a portion of the reagent.

Fabric filters are typically used to capture the reacted product as well as the particulate.

Electrostatic precipitators are less frequently used due to their lower absorption efficiency.

Applications include coal-fired boiler, cement, glass, biomass, steel and waste-to-energy plants.

More details on the automation of these systems is found in N031 Industrial IOT and Remote O&M.

FLSmidth has signed a contract for a greenfield cement plant with Abay Industrial Development Share Company. The plant will be located near the city of Dejen in Ethiopia. The contract is valued at around €100 million.

The order includes design and engineering, full equipment supply, automation systems, installation and commissioning as well as training and extended supervision. Completion of the order is expected during the 2nd quarter of 2022, and once fully operational the plant will have a capacity of 5000 tonnes per day.

The dialogue between FLSmidth and Abay Industrial Development S.C. began in November 2017 and has now led to the present order for one of the most modern cement plants on the African continent.

"This greenfield plant will be utilizing the most modern and energy-efficient equipment with the lowest possible environmental impact. I am also very pleased that with training and supervision included in the contract, we will help create 300 jobs in this region — as well as a source of cement for continuing regional development. This contract once again underlines our position as the preferred supplier of sustainable and productivity-enhancing solutions to the global cement industry," said Jan Kjaersgaard, President, Cement, FLSmidth.

The Aïn Touta Cement (SCIMAT) plant near Batna, Algeria, has spent US$10 million on a new filter. The investment is part of a group of improvements intended to increase production at the unit in 2019, according to Le Courrier d'Algérie newspaper. The company is also implementing a new integrated administration system.

Mamuka Bakhtadz, the Prime Minister of Georgia, has officially opened a US$100 million upgrade to HeidelbergCement’s Kaspi cement plant. Work on the new dry production line at the site started in mid-2016. A filtration system and equipment for continuous emission control were installed to allow for online monitoring of the plant's dust and emission volumes. The project was supported by the Georgian Co-Investment Fund and Honeywell Partners.

Wyoming Governor, Mark Gordon, is looking at least three potential sites for the experimental coal-generating plant he wants to build in the state.

The Gillette News Record reports that Gordon told the Wyoming Press Association Convention that the Integrated Test Center near Gillette is one possibility. The other potential sites include the Dave Johnson Power Plant in Converse County and the Jim Bridger Plant in Sweetwater County.

Gordon has asked state lawmakers for $10 million to build a 5-MW power plant that would be capable of capturing at least 75 percent of its carbon emissions.

The money would be used to leverage up to $40 million in federal grant funding to supplement the work of the test center, a research facility at the Dry Fork Station power plant.

The Indian Government’s National Clean Air Program proposes a “tentative” target of reducing PM2.5 and PM10 fine particle pollution by between 20 and 30 percent by 2024 compared to 2017 levels. The plan proposes increased air quality monitoring and the development of city-specific action plans for 102 cities designated as in breach of air quality standards. However, even if the reduction targets are met, India’s most polluted cities would still well exceed World Health Organization standards. The plan provides for no binding targets or enforcement mechanisms but notes there is a need to ensure “stringent compliance” of all coal-fired power plants with new emission standards by 2022. A study recently published in the medical journal The Lancet estimates that air pollution in India caused up to 1.24 million premature deaths in 2017.

The Environmental Protection Agency (EPA) is proposing a revision to its response to the U.S. Supreme Court decision in Michigan v. EPA which held that the EPA erred by not considering cost in its determination that regulation under section 112 of the Clean Air Act (CAA) of hazardous air pollutant (HAP) emissions from coal- and oil-fired electric utility steam generating units (EGUs) is appropriate and necessary.

After considering the cost of compliance relative to the HAP benefits of regulation, the EPA proposes to find that it is not "appropriate and necessary" to regulate HAP emissions from coal- and oil-fired EGUs, thereby reversing the Agency's prior conclusion under CAA Section 112(n)(1)(A) and correcting flaws in the Agency's prior response to Michigan v. EPA.

We further propose that finalizing this new response to Michigan v. EPA will not remove the Coal- and Oil-Fired EGU source category from the CAA Section 112(c) list of sources that must be regulated under CAA Section 112(d) and will not affect the existing CAA Section 112(d) emissions standards that regulate HAP emissions from coal- and oil-fired EGUs.

We are soliciting comment, however, on whether the EPA has the authority or obligation to delist EGUs from CAA Section 112(c) and rescind (or to rescind without delisting) the National Emission Standards for Hazardous Air Pollutants (NESHAP) for Coal- and Oil-Fired EGUs, commonly known as the Mercury and Air Toxics Standards (MATS).

The EPA is also proposing the results of the residual risk and technology review (RTR) of the NESHAP that the Agency is required to conduct in accordance with CAA Section 112. The results of the residual risk analysis indicate that residual risks due to emissions of air toxics from this source category are acceptable and that the current standards provide an ample margin of safety to protect public health. No new developments in HAP emission controls to achieve further cost-effective emissions reductions were identified under the technology review.

Therefore, based on the results of these analyses and reviews, we are proposing that no revisions to MATS are warranted.

Finally, the EPA is also taking comment on establishing a subcategory for emissions of acid gas HAP from existing EGUs firing eastern bituminous coal refuse.

DATES: Comments. Comments must be received on or before April 8, 2019. Under the Paperwork Reduction Act (PRA), comments on the information collection provisions are best assured of consideration if the Office of Management and Budget (OMB) receives a copy of your comments on or before March 25, 2019.

Chengdu Changfeng Orders EAF Quantum Electric Arc Furnace and Ladle Furnace from Primetals Technologies

Chinese steel producer Chengdu Changfeng Steel Group Co., Ltd. (Chengdu Changfeng) placed an order with Primetals Technologies to supply an EAF Quantum electric arc furnace and a ladle furnace for its plant in Dujiayan city, Sichuan Province. This marks the 9th EAF Quantum for China. The EAF Quantum furnace is designed to handle scrap steel of vary varied composition and quality. The electrical energy requirement of the electric arc furnace is extremely low because the scrap is preheated. This reduces both the operating costs and the CO2 emissions. The twin ladle furnace sets the desired steel grades and the correct casting temperature. The new furnaces are scheduled to be commissioned in early 2020.

Chengdu Changfeng is a medium-sized state-owned enterprise based in Chengdu, Sichuan Province. The company operates three steel branches, one oxygen production company, and one mechanical manufacturing and processing company. For the new EAF Quantum electric arc furnace and the twin ladle furnace, Primetals Technologies will supply the complete mechanical and electrical process equipment and the automation technology. This includes the automated scrap yard management, the automated charging process, automation of the oxygen injection and sand refilling, as well as the Level 2 automation which makes the plant ready for Industry 4.0.

The EAF Quantum developed by Primetals Technologies combines proven elements of shaft furnace technology with an innovative scrap charging process, an efficient preheating system, a new tilting concept for the lower shell, and an optimized tapping system. This all adds up to very short melting cycles. The electricity consumption is considerably lower than that of a conventional electric arc furnace. Together with the lower consumption of electrodes and oxygen, this gives an overall advantage in the specific conversion cost of around 20 percent. In comparison to conventional electric arc furnaces, total CO2 emissions can also be reduced by up to 30 percent per metric ton of crude steel. An integrated dedusting system with modern automatic off gas control fulfills all environmental requirements.

Tenova LOI Thermprocess Will Supply a Large Aluminum Recycling Furnace to Italian Company

Tenova LOI Thermprocess, supplier for custom-made heat treatment lines and furnaces and specialist for recycling plants for contaminated aluminum scrap, has received an important order from Fonderie Pandolfo, Italy, for the delivery and installation of a Twin Chamber Melting Furnace TCF®.

Fonderie Pandolfo is the recycling and melting enterprise within the Panalco Holding, specialized in processing of aluminum, mainly for extrusions. The casted billets are mainly extruded in the extrusion shops of the main European extruders.

Currently, over 60,000 tons of refined and recycled aluminum are molten and cast into semi-products. Fonderie Pandolfo already operates a set of TCF® and casting furnaces supplied by Tenova LOI Thermprocess in 2008. The new installation will double the production rate, aiming to satisfy the continuous market requests.

The TCF®, with a capacity of 65,000 tons/year, is designed for aluminum scrap recycling. In order to cover a broad range of scrap and contamination degree, the TCF® combines pre-treatment and melting in one furnace.

The beneficial TCF®-process relies on the efficient melting by limiting dross formation due to pre-treatment, while the evolving Volatile Organic Contents (VOCs) are combusted completely in the furnace to decrease the overall energy consumption and fulfill the most restrictive environmental regulations.

By combining regenerative air heating (CCR) and optimized thermal treatment of the organic scrap components, this proven furnace technology reaches an unmatched grade of energy and metal efficiency. A sophisticated automation technology, applied by Tenova LOI Thermprocess with the aim to streamline a fully automatic charging machine, increases efficiency further.

The scope of supply contains the turnkey-installation, including a state-of-the-art flue gas treatment plant.

Sven Kristensson, CEO of Nederman, provided the following comments in their year-end report:

"After the challenging 3rd quarter when our US operations were hit by production and distribution interruptions in the wake of Storm Florence and the caution in China increased further, it is very satisfying that the year's 4th quarter was strong. Incoming orders in the quarter grew to SEK 967.8 million (815.9), equivalent to a currency-neutral growth of 13.4 percent. Sales saw an even stronger development and amounted to SEK 1069.0 million (860.0) during the quarter, corresponding to a currency-neutral growth of 19.4 percent. Adjusted operating profit increased to SEK 126.7m (106.8).”

“The positive development during the final quarter of the year also means that we see a strong development for the full year for 2018. Incoming orders totaled SEK 3479.5 million (3,157.3), equivalent to a currency-neutral growth of 7.4 percent. Sales amounted to SEK 3553.9 million (3148.5), corresponding to a currency-neutral growth of 10.1 percent. The adjusted operating profit rose to SEK 308.1 million (285.8), corresponding to an adjusted operating margin of 8.7 percent (9.1). The slightly lower margin is mainly explained by increasing investment in innovation and product development. Earnings per share rose to SEK 5.79 (5.31). A dividend per share of SEK 2.30 (2.00) is proposed.”

“During the quarter, Nederman acquired the Swiss group Luwa. This has enabled us to strengthen our operations with a global market leader within the air filtration field for the fiber and textile industries. Luwa's significant market presence and its strong position in the fiber and textile market which is an important market for Nederman, linked with our global organization, will make the Nederman Group a more complete and attractive partner for our customers, not lst in APAC where Luwa has a strong position.”

“Just as during the 3rd quarter, Nederman Insight has continued to develop positively. It is clear that our customers have a great need to establish, with the help of Nederman Insight, a digital and online business with all the benefits this provides. In 2018, Nederman Insight has taken the step from idea to the establishment of significant business operations. We have recently received orders for Insight solutions from customers in the wood industry, foundries and from medical technology companies among others. Nederman Insight as a whole is now approaching an annual turnover equivalent to SEK 250 million. Although Nederman Insight already forms a significant part of the Nederman Group, we are still only at the beginning of the journey aimed at establishing Nederman as the obvious digital partner for our customers.”

“Many of our markets are characterized by continued uncertainty. The risk of trade conflicts and financial uncertainty means that decisions about major investments are being delayed and that large projects are being postponed. Despite these geopolitical challenges, our basic view is one of cautious optimism. Environmental issues will continue to be important for our customers and in 2018, we have strengthened our positions in several central areas where we see that future growth will occur."

Donaldson has introduced a connected solution that monitors dust and fume collection equipment and prompts owners to take early, cost-saving maintenance actions. Using cloud connectivity, the technology gathers real-time data from an operating collector, applies Donaldson’s filtration analytics in the cloud and relays actionable insights back to the owner via a web-based dashboard and text or email alerts. The technology can be installed on existing or new industrial dust and fume equipment and includes: sensors to gather data in real-time as the equipment operates; IoT Gateway to send the data to the cloud; data analytics developed by Donaldson data scientists to convert the data into meaningful insights; Web-enabled dashboard to view trends and historical behavior; automated email alerts and reports providing operators with suggested actions. The technology provides intelligent insights that enable earlier detection of performance concerns so that operators have the chance to address them before they become disruptive and impact production.

Camfil APC’s New Quad Pulse Package 2 Dust Collector Increases Filtration Capacity with Two Main Cartridges

Pharmaceutical processing facilities that produce high concentrations of fine, hazardous, combustible and nuisance dust need an industrial dust collector that is cost effective to operate and easy to maintain on the plant floor or in production suites. The Quad Pulse Package 2 (QPP2) dust collector from Camfil Air Pollution Control (APC) has two main filter cartridges designed for 590-1765 cubic-feet-per-minute air volumes to increase filtration capacity. The QPP2 also features a cleanable filter system that allows manufacturers to run continuous production processes and avoid frequent, expensive filter replacements.