FABRIC
FILTER
NEWSLETTER
October 2021, No.552
MARKETS
EIA Projects Increases in Global Energy Consumption and
Emissions Through 2050
CHP will be an Important Component of a Net Zero Policy
Make it Easy to Buy a Better Pump, Valve, or Filter
GAS TURBINES
Gas
Turbines in Oil and Gas Industry Provide Difficult Challenges
for Intake Air Filters
IRON AND STEEL
Babcock & Wilcox Renewable Awarded $35 Million Contract to
Supply Waste-to-Energy Technologies for Facilities in Greenland
ADDITIVE MANUFACTURING
Parker Launches Advanced Competitive Fit Replacement Filters
REGULATIONS
World Health Organization
Tightens Air Pollution Guidelines
MARKETS
EIA Projects Increases in Global Energy Consumption and Emissions Through 2050
The U.S. Energy Information Administration (EIA) projects that, absent
significant changes in policy or technology, world energy consumption will grow
by nearly 50% between 2020 and 2050. In its International
Energy Outlook 2021 (IEO2021), EIA projects that strong economic
growth, particularly with developing economies in Asia, will drive global
increases in energy consumption despite pandemic-related declines and long-term
improvements in energy efficiency.
If current policy and technology trends continue, global energy consumption and
energy-related carbon dioxide emissions will increase through 2050 as a result
of population and economic growth.
According to the IEO2021 Reference case, which projects future energy trends
based on current laws and regulations, renewable energy consumption has the
strongest growth among energy sources through 2050. Liquid fuels remain the
largest source of energy consumption, driven largely by the industrial and
transportation sectors.
“Even with growth in renewable energy, without significant policy changes or
technological breakthroughs, we project increasing energy-related carbon dioxide
emissions through 2050,” said EIA Acting Administrator Stephen Nalley.
Renewables will be the primary source for new electricity generation, but
natural gas, coal, and increasingly batteries will be used to help meet load and
support grid reliability.
EIA projects electricity generation to almost double in developing non-OECD
countries by 2050. Falling technology costs and favorable laws and regulations
mean that much of the new electricity generation will come from renewable energy
sources, although natural gas, coal, and batteries will remain critical parts of
the electric grid, backing up solar and wind resources.
“The worldwide push to generate more electricity from renewables and also
increase electric grid reliability could push more expansion of battery storage
on a global scale,” Nalley said.
Oil and natural gas production will continue to grow, mainly to support
increasing energy consumption in developing Asian economies.
Driven by increasing populations and fast-growing economies, EIA projects that
consumption of liquid fuels will grow the most in non-OECD Asia, where total
energy consumption nearly doubles from 2020 to 2050. EIA projects that
consumption will outpace production in these countries, driving an increase in
imports of crude oil or finished petroleum products, primarily from the Middle
East.
“The fast-growing economies in Asia could combine to become the largest importer
of natural gas and crude oil by 2050, given their significant increase in energy
consumption,” Nalley said.
The full IEO2021 is available on
the EIA website.
Combined heat and power can
make a big contribution to achieving net zero CO2 emissions.
When applied with coal firing
CHP has lower net CO2 emissions than a gas turbine as shown in the following
table.
Many CHP plants are fired with
gas turbines or reciprocating engines. Here is a DOE analysis for the U.S.
Many of the CHP plants are
using biomass. So their net contribution is negative. This is due to the
reduction in CO2 emissions from facilities being heated or cooled.
A few CHP plants are moving
forward with carbon sequestration. This makes them the most carbon negative
option. Whereas wind and solar are net zero BECCS with CHP would be a negative
1.3 tons of CO2 per unit of energy.
A coal plant is plus 1. If it
is converted to biomass and CCS it would be reducing CO2 at a faster rate than
it formerly was producing. So in 20 years converted plants could reduce CO2
emissions by the amount they emitted in the last 28 years.
GE predicted a few yeas ago
that CHP would replace large scale generation. The basis for this idea is the
huge increase in efficiency and the elimination of small CO2 sources such as gas
heaters.
The CHP Alliance held a
conference on hydrogen and CHP last week. Speakers from Siemens and other large
turbine companies were optimistic about hydrogen fueled CHP.
Another potential is commercial
greenhouses. The 12 largest in the U.S. have a 680 MW capacity. Most commercial
growers use some of the CO2 produced to inject into the ambient air in the
greenhouse. At 1000 ppm many crops grow up to 40% faster.
In Europe biomass fired CHP
plants are supplying a large amount of power and heat. Several have also added
CO2 capture and sequestration.
CHP plants around the world can
be identified and the potential analyzed. They all have detailed permits with
information not only on the boilers but also the processes. Any process which
has the potential to emit air or water pollutants is identified.
Databases and project tracking are found at http://home.mcilvainecompany.com/index.php/databases/42ei-utility-tracking-system
Make it Easy to Buy a Better Pump, Valve, or Filter
Every supplier is striving to
show why his product is a better choice than the one the prospect is using.
Revenues for companies selling air, water, and combustion related products and
services are over $600 billion per year.
Fifty percent of these products
are in the high performance category where price is secondary and the service is
unique, critical, or severe.
There needs to be a better way
for purchasers to determine which product will best meet the high performance
requirements. This could increase revenue and EBITA by $45 billion.
If the product is already
performing at the prospect’s plant or is the market leader, the default position
is that this is the best performing product.
Claims of a new and better
product fall on deaf ears unless there is supporting evidence relevant to the
unique requirements of that plant in that location and for that application.
There is no system in place to
make it easy to demonstrate a better product for a specific niche. As a
result you have two strategies. One is to minimize R&D and be content with EBITA
of less than 15%.
Another strategy is to focus on
very narrow niches. Several companies with this strategy are enjoying EBITA
above 30%.
However without a system to
easily demonstrate superiority of a better product, the pursuit of these niches
is challenging. Success has primarily come from acquiring existing small
companies focused on a niche.
As a result, these high EBITA
companies are not revenue market leaders. Ninety-five percent of the $300
billion of revenues in the high performance segment accrue to companies with
EBITA of less than 15%.
Despite all the potential of
the internet it is no easier to make the right decisions than it was in 1974
when McIlvaine introduced thousand-page loose leaf decision guides
A new approach is needed. It
involves publishers, conference organizers, associations and the suppliers of
systems and products.
McIlvaine proposes a holistic program as explained at http://home.mcilvainecompany.com/index.php/30-general/1658-holistic-content-marketing-program
The program starts with a
market forecast in each niche.
Video https://youtu.be/JPCduQKtJVY
Power Point
Most Profitable Market Support Services
GAS TURBINES
Gas Turbines in Oil and Gas Industry Provide Difficult Challenges for Intake Air
Filters
Harsh
weather conditions, high levels of airborne particulate and salt ingress are
just some of the challenges faced by gas turbine operators in the oil and gas
industry.
Often sited in remote locations such as jungles, deserts, offshore platforms
and FPSOs, gas turbines used in the oil and gas industry typically encounter
extremely challenging operating environments. High levels of small particulate
in the form of sand, dust and shot-debris from drilling, salt aerosols in
offshore and coastal locations, and harsh weather conditions all threaten the
performance and health of a gas turbine. In addition, particularly in offshore
locations, severe space and height limitations pose further challenges to
efficient operation.
Today's operations require high availability and low downtime rates from their
turbines. However, in the oil and gas industry, the environment can threaten
the trouble-free operation of a gas turbine. Due to the very large quantities of
air that turbines require for operation, airborne contaminants can pose a
significant challenge to the ongoing health of these precision pieces of
rotating equipment. The Parker three Altair System2 high efficiency bag filters,
including the HVL, HVX and HVV, protect gas turbines against high levels of
sub-micron particulate and provide a barrier against more common contaminants
like wet and dry aerosols, drilling muds, grit blasting debris, and
hydrocarbons.
IRON AND STEEL
Since its first industrial
installation, more than thirty years ago, Tenova has continuously improved the
Consteel® system to meet clients’ needs, and it currently represents
the best EAF charging solution on the market in terms of efficiency and
sustainability, as confirmed by the numerous references worldwide. The fumes
from the EAF are used to pre-heat raw materials inside the pre-heating section
and are then sent without pollutants, to a plant fume cleaning system.
The new Consteel® for Fujian Sanbao is designed to be fed
with low-density scrap and its conveyor is the widest ever installed in China.
The equipment was designed to allow the customer to have high flexibility for
raw materials, making possible to use different types of scrap, including
bundles and hot metal.
WASTE
TO ENERGY
Babcock & Wilcox Renewable Awarded $35 Million Contract to Supply
Waste-to-Energy Technologies for Facilities in Greenland
Babcock & Wilcox announced that its B&W Renewable segment has been awarded a
contract for more than $35 million by Greenland’s national waste management
company, ESANI A/S, to supply and install advanced combustion, emissions control
and related equipment for its new municipal waste-to-energy facilities.
The facilities, to be built in the cities of Nuuk and Sisimiut, will provide
district heating for residents and businesses while also eliminating methane – a
greenhouse gas created by waste as it decomposes in landfills. In addition to
using municipal waste, the facilities also will process waste recovered from
existing landfills, reducing future methane emissions from those landfills. B&W
Renewable’s technology will provide the ability to process all of Greenland’s
municipal waste.
“Waste-to-energy technologies are some of the most effective solutions for
combatting climate change by reducing methane emissions from landfills and can
be combined with carbon capture technologies to further reduce greenhouse gas
emissions,” said Jimmy Morgan, B&W Chief Operating Officer. “Using B&W
Renewable’s proven waste-to-energy and environmental technologies, operators can
generate clean energy while reducing the amount of trash in landfills,
protecting the air and water from emissions and runoff, and fighting climate
change. B&W Renewable’s technology also provides a fully sustainable solution,
now and in the future, to process municipal waste while helping to protect
Greenland’s pristine and fragile arctic environment.”
“Global demand for waste-to-energy technology is substantial, and B&W Renewable
is pursuing additional significant opportunities to deploy our world-class
combustion and environmental technologies for customers in Europe, Asia, North
America and elsewhere,” Morgan said.
According to U.S. Environmental Protection Agency data, waste-to-energy can be a
powerful solution for reducing greenhouse gas emissions. One ton of landfilled
waste emits the equivalent of 3.42 metric tons of carbon dioxide’s estimated
Global Warming Potential (GWP) on a 20-year basis, which compares to only .001
metric tons of carbon dioxide GWP when a ton of waste is used to produce
baseload energy.
B&W Renewable’s project scope includes the supply of advanced Vølund DynaGrate® combustion
grates as well as boilers, waste feeding systems, a Vølund DynaDischarger® ash
extractor, GMABTM flue gas cleaning systems and advanced control and monitoring
systems. B&W Renewable also will provide installation and commissioning services
for the facilities, which are scheduled for completion in 2023 and 2024.
ADDITIVE MANUFACTURING
At the trade show formnext from 16-19 November 2021, ULT AG will demonstrate how
extraction and filtration systems can support SLM processes (selective laser
melting) as well as post processing tasks.
The German enterprise ULT AG was one of the first pioneers to bring filter
technology as well as gas cleaning systems to the additive manufacturing market.
This know-how has been improved throughout the years. The company continuously
develops specific extraction solutions because without these technologies clean
processes in additive manufacturing would be impossible.
A complete newly developed, unique extraction and filtration system will be at
the heart of ULT’s show appearance. It is a modular concept with well-proven
standard components that can be individually adapted to new or specific
applications.
This raises the performance range of ventilation systems in the field of
additive manufacturing to a completely new level.
“Due to our 20 years of experience in the additive manufacturing market, we are
able to quickly and easily offer solutions that go far beyond standard systems
for inert gas cleaning or fume filtration in post processing”, explains Boris
Frühauf, Key Account Manager additive manufacturing and laser technologies with
ULT. “In addition
to networking opportunities and
a general presence, our goal at formnext is to receive and collect news and
innovations that we then refine as part of our intensive research work.”
Apart
from extraction
and filtration technologies,
ULT provides solutions for process
air drying.
The modular systems of the ULT Dry-Tec® series ensure ideal air humidity
conditions, among others for powder handling or the entire process.
W. L. Gore & Associates has introduced GORE® LOW DRAG Filter Bags for use in
TiO2 micronizer and drier operations. For the past five years, Gore’s
proprietary GORE LOW DRAG Filter Bag technology has provided a sustainable and
low-cost-of-ownership solution for a wide range of product collection
applications, such as TiO2 packing bins. Now, the benefits of this technology
are extended to high-temperature pulse-jet TiO2 applications.
Comprehensive pilot programs have confirmed that GORE LOW DRAG Filter
Bags can provide significant value in specific high-temperature TiO2 operations
such as micronizers and driers:
A more
easily-cleaned filtration surface: This allows operators to
reduce pulsing pressure and frequency, without any reduction in
desired production levels.
Increased bag life: By reducing the level of
mechanical stress during cleaning, bag life has been shown to
increase by as much as 50% or more.
Improved process stability: Gore’s
proprietary membrane technology enables lower, and more stable,
differential pressure (dP) between cleanings, which supports a
more stable process.
Optimized throughput and emissions: GORE LOW
DRAG Filter Bag technology enables higher airflow than standard
filter bags, and pilot studies have reported improved production
rates, along with lower emissions.
Gore Product Specialist Steven
Aubuchon explained the reasoning behind this new product introduction: "The
successful adoption of GORE LOW DRAG Filter Bags in TiO2 feed bins and other
adjacent applications led us to develop an improved technology that could offer
similar benefits in high-temperature TiO2 processes such as micronizers and
driers. The specific technology improvements we made have demonstrable
performance benefits, including longer bag life, better process stability, and
reduced emissions."
Our proprietary GORE LOW DRAG
Filter Bag technology provides value precisely because it can address so many
issues the TiO2 industry faces today: the need to optimize output while
enhancing environmental compliance and process stability, and at the same time,
reducing cost of ownership," said Aubuchon.
New Donaldson Connected Filtration Service Features for Dust Collectors
Help Manufacturers Reduce Energy Use and Operating Costs
Donaldson Company, Inc. has added three new features to iCue™ Connected
Filtration Service’s continually evolving list of performance monitoring and
data acquisition capabilities.
The subscription-based iCue service remotely monitors a facility’s dust
collection equipment and provides operational insights directly to end users.
This information can help manufacturers reduce unplanned downtime, support
efficient maintenance and operations, and automatically capture compliance and
sustainability data. The three new features are the eighth release of the
ongoing capability and improvement updates to the service since its launch 24
months ago. The three new features are:
Fan energy
monitoring allows users to assess the energy demands of a dust
collector, with both fan power and daily energy use metrics.
Reducing energy consumption is a key initiative for many
manufacturers’ sustainability goals and dust collectors can be
large consumers of energy. This data can help users balance the
costs of filter replacement with energy usage.
Bin level monitoring alerts users when dust collector bins are nearly full, removing guesswork about when to empty bins, and preventing filter damage and the mess caused by dust overflow. This sensor is especially useful in operations where bins fill frequently.
Pulse valve
health monitoring has been expanded to work on collectors with
up to three (from original support of one) manifolds to help
detect compressed air problems or failed pulse valves that can
affect filter life. This feature helps users prevent unplanned
downtime and emergency repairs.Our iCue connected filtration
service features continue to evolve as we invest in research and
development to ensure we can provide the information our dust
collector customers need,” said Wade Wessels, Global Director of
Connected Solutions for Donaldson. “These three new features
give EHS, maintenance and sustainability teams the real-time
data required for compliance reporting and making informed
maintenance decisions that help reduce total energy use and
operational costs.”
The iCue Connected Filtration
Service can be retrofitted to most existing Donaldson and non-Donaldson dust
collectors and is provided free of charge for six months on select Donaldson
dust collector models sold in Europe, Canada and the United States.
Parker Launches Advanced Competitive Fit Replacement Filters
The Industrial Gas Filtration and Generation Division of Parker Hannifin
Corporation has introduced two new aftermarket cartridge filters. Parker designs
filters to meet special applications and manufactures aftermarket filters for
most OEM dust collection equipment with design improvements to help customers
improve their bottom line.
The division’s newest development is a replacement cartridge filter for an OEM
brand dust collection system. The key advantage to this filter is the enhanced,
more conventional design. This filter is constructed without the inner conical
filter the OEM included, creating a greater pleat depth. For enhanced sealing,
the filter has a wider gasket contact area than the OEM filter. To resist
bowing, the replacement cartridge is constructed with a stiffer, and heavier
gauge sheet metal top pan and the robust filter design also includes a
galvanized expanded metalcore, urethane potting compound and four 1” wide
reinforcement straps.
Another notable feature of this pulse-jet cartridge filter is that it can
directly interchange with the OEM filter without any required modification of
the dust collector. This enables the replacement cartridge to be compatible for
use in any application currently using the OEM filter with similar media.
“This replacement cartridge was engineered to solve problems customers
experience with the OEM brand filter. With greater pleat depth and proven design
enhancements, beta site customers report lower pressure drop and longer filter
life,” said Jeff Canfield, senior product engineer, Industrial Gas Filtration
and Generation Division.
Parker has developed dozens of OEM brand competitive fit filters, including a
52” cartridge using a continuous, full-height pleatpack rather than the original
configuration of stacking and joining two 26” tall cartridges. For customers,
this means less potential for leaks, no wasted media at the connection of the
two sections and less labor and materials needed to make one full-height
pleatpack. Parker delivers improved performance - ultimately leading to a safer,
cleaner and lower maintenance work environment.
New System Control Accelerates Digitization of Extraction Devices
ULT AG presents a new system control. From now on, it will be integrated into
the company's cartridge filter systems, which will significantly expand their
communication capabilities and thus offer users convenient evaluation and
control options.
This ability is based on an integrated PROFINET interface, a device that enables
communication with external systems, e.g., laser processing, painting or
soldering systems, and, furthermore, the reading of operating states, such as
filter occupancy, power, process gas temperature, error messages, and much more.
ULT AG offers the PROFINET interface as a standard in its large fume extraction
devices.
An essential part of the new system control is a display with plain text. This
enables, for example, the reading of operating and system states, status
messages for the extraction system and device parameterization. The display also
increases serviceability, as relevant data can be called up quickly and easily.
Sensors integrated into the extraction systems send important operating
information to the new control, such as the filter status, fill levels of
discharge containers or a filter aid metering, error messages in the case of
blocked suction or exhaust pipes, and various others.
An integrated memory card for data logging is also part of the new system
control, as is the option to connect to cloud services. Further communication
bus systems can also be supported upon request.
REGULATIONS
World Health Organization Tightens Air Pollution Guidelines
The World Health Organization’s (WHO) new Global Air Quality Guidelines has cut
the recommended standard for PM2.5 fine particle pollution from 10 micrograms
per cubic meter (μg/m3) to 5 µg/m3. It also slashed the recommended nitrogen
dioxide level by 75 percent from 40 µg/m3 to 10 µg/m3. The WHO estimates up to
80 percent of the deaths caused by PM2.5 fine particle pollution could be
avoided if the new standard is implemented. Estimates of the annual death toll
from PM 2.5 pollution are between 3 million and 8 million deaths per year. The
WHO’s air pollution guidelines were last updated in 2005.
Back to Fabric Filter Newsletter No. 552 Table of Contents