FABRIC
FILTER       NEWSLETTER 

  

 

May 2022, No.559

MARKETS

 METALS 

 

WELDING FUMES

 

BIOMASS

 

BIOFUEL

 

COMPANY NEWS

 PRODUCT NEWS

 

ENFORCEMENT ACTIONS

 

MARKETS

 

Fabric Filter Market Changing Faster Than Any Time Since 1960

In the 1960s pulse cleaned bags rapidly obsolesced shaker bags. New high temperature fabrics were introduced which allowed greater penetration into the power and other markets dominated by precipitators.

 

The 2020s is going to be equally dynamic in terms of the products, applications, and geographies.

 

Products: Previously the element designs were primarily bags and cartridges. The cartridges were pleated and mostly cellulose. They were applicable only to light and dry applications. Now new pleated designs with higher temperature fabrics have created a major new category. Because the pleated synthetic media filters are typically less than 8 inches in diameter (the typical paper cartridge is more than 8 inches in diameter), the new segmentation for the pleated filters is labeled “cartridges <8 inches diameter”.

 

Another development is the ceramic filter. It can operate at very high temperatures. If the gas has to be cooled to 500F in order to be filtered a large amount of energy is wasted. These filters can not only remove the fine particulate but with direct sorbent injection can also remove acid gases. The ceramic filter can also include an embedded catalyst. So one vessel can replace three: the particulate filter, acid gas scrubber and selective catalytic NOx control unit.

 

 

 

Applications: Biomass combustion followed by carbon sequestration is the most promising carbon negative technology. A coal plant like Drax which switches to this technology takes out as much CO2 from the atmosphere as it was previously adding. So this is a double digit growth potential for fabric filters.

 

Geographies:  The Russian invasion is creating expanded markets for fabric filters in Europe.  The growth of biomass combustion will offset  use of natural gas. The agricultural disruption will  create a spurt in fertilizer manufacturing plants in ROW. Russa and Belarus combined are the largest potash producer. Russia has large reserves of metals.

 

Chinese filter bag suppliers have a significant share of the international markets. The COVID shutdown creates a short term crisis. Longer term the autocratic Chinese-Russian coalition could permanently change the market.

 

The McIlvaine Company is making continuous changes to the Fabric Filter: World Market forecasts.  More than 50,000 new forecasts by product type have been added. All the forecasts are being updated every few months in order to reflect the changes.

Information on the report is found at http://home.mcilvainecompany.com/index.php/markets/air/n021-world-fabric-filter-and-element-market

 

The report provides the foundation for an Evidence Based Sales Strategy. More information on this strategy is available from Bob McIlvaine.  He can be reached at 847 226 2391 or rmcilvaine@mcilvainecompany.com

 

The Optimum Russian Invasion Outcome for AWE Suppliers

 

The short term outcome will be negative. So the goal will be to limit the damage. Long term there is the complete range of outcomes from a planet destroyed by nuclear weapons to one where there is unified pursuit of environmental and social goals.

 

1. Practical rather than moral guidance.

It is more productive to view these goals in practical rather than moral terms. From a practical perspective people band together and give up certain freedoms in return for benefits which outweigh the sacrifices. The willingness of the Ukrainian people to risk death rather than live under Russian rule is extremely admirable. However in practical terms, the Ukrainians have had the firsthand experience of living in relative poverty and coercion. They understand that life is a gamble and that you should bet on the best life quality option. Your chances of dying  in a car accident during your life time are 1/200. But everyone sees this as a good gamble. The safest and most economical life option is to be locked in solitary confinement. But no one will choose this option because the goal is life quality and not longevity.

 

Viewing the opportunities through a practical rather than moral lens is necessary to create the optimum strategy.

 

The alliance to support Ukraine can be as narrow as just the democratic countries of the world or all countries who are committed to national sovereignty. The African nations have achieved peace by agreeing to preset boundaries regardless of ethnic or historical  experience.

The coalition based on national sovereignty has been the norm  for decades. It peaked prior to  to the Russian invasions of Georgia and Crimea.

 

One of the positive factors has been the participation of China who has developed strong trading relationships with many countries. Many international companies have major operations in China. They serve the domestic market and are utilized for export around the world.

 

The optimum result for AWE suppliers will be inclusion of China with the proviso that Taiwan’s sovereignty will be protected.

 

The AWE industry has more to gain from free trade than it loses in tariffs. More than 70% of the revenues are generated In other than the home country. There is a boom in the U.S.

semiconductor industry. The two leading suppliers of HEPA filters are Daikin and Camfil. Neither is U.S. based. International companies will supply the pumps, valves, tubing, fans, and automation systems.

 

It is therefore concluded that the Sovereign Nation Alliance is the optimum result for the AWE suppliers.

 

2. The optimum environmental-cost balance for the AWE industry

There is a dilemma relative to using energy sources in Europe which generate more greenhouse gases to avoid the use of Russian Energy. Volkswagen  announced this week that it will continue to operate its large coal burning combined heat and power plant. The plan had been to switch to gas. NATO believes it is important that Russia does not generate oil and gas revenues. Volkswagen is following the lead of a number of coal-fired boiler operators.

 

The goal is not to change the net zero goal of 2050 but achieve these reductions sometime in the next two decades.

 

Some argue there is a tipping point and that once the CO2 levels reach a certain level reversal is impossible.

 

Fortunately for Volkswagen and other coal burning plants there are carbon negative options.

The additional CO2 generated by Volkswagen in the 2020s can be offset by carbon negative operations in the 2030s.

 

One option is BECCS. It can be progressive. This is the strategy employed by Drax. Coal is progressively supplanted by biomass When 100% biomass is burned Drax is carbon neutral. It is now building a CO2 pipeline which will allow sequestration in the North Sea.

 

There is the option for other companies to use the pipeline for CO2 they generate.

 

Preservation of coal plants for future carbon negative operation is significant. Once this plant is demolished and replaced with wind or solar there is carbon neutral generation. However virtually all strategies for achieving net zero in 2050 rely on some carbon negative strategy.

For AWE suppliers the optimum result of the current crisis is alliance of nations committed to national sovereignty and who adapt a flexible policy to balance economic, political, and social goals.

 

METALS

 

Hindalco Awards Contract for Flue Gas Desulphurization (FGD) System to W. L. Gore & Associates

 

Hindalco has awarded a contract to W.L. Gore for FGD control with its Sorbent Polymer Catalyst technology at the Renusagar Site for an 80MW unit. The GORE® SO2 Control System is a catalytic, reagent-less FGD system designed to fit tight spaces, consume less water, and reduce operating costs.

 

The GORE® SO2 Control System contains fixed catalyst modules that eliminate the need for reagents. These modules, developed by scientists at Gore, convert SO2 from the flue gas into sulphuric acid which is concentrated into a saleable grade of acid suitable for fertilizer production and other uses.

 

Gore’s modular, passive system is easy to operate, and can be configured to fit within space-constrained sites. It consumes less water and carries significantly lower operating costs than traditional technologies which enables compliance at the lowest total cost of ownership for power plant operators.

 

WELDING FUMES

 

Nederman Addresses Working Conditions in Welding and Automotive Workshops

 

Nederman installed a complete solution of extraction units in the workshops for welding and auto mechanics in VTI Bruges Campus in Belgium, allowing a healthy work environment for the students.

 

The VTI Bruges Campus fits into the ‘Scholen van Morgen’ (Schools of Tomorrow) project by the Flemish government. It´s the third largest construction project of its type in the Flanders region and becomes the model for modern vocational education, both in the field of new and sustainable techniques and in the educational vision. The technical school is located on a former industrial site, which has a total area of 17,500m² and offers space for classrooms as well as mechanical, electrical and automotive workshops. With more than 30 welding stations, several automotive workshops and a CNC machining center, the campus was in need of a complete extraction solution to provide a healthy work climate for their students. Both welding fumes and vehicle exhaust are known carcinogenic, and exposure can lead to several kinds of cancer as well as lung diseases, damage to the central nervous system, and other hazardous health problems. When machining metal with CNC devices, coolant is added which creates oil mist, which is harmful to human health and has to be extracted and filtered. Measures to remove the hazardous particles from the air had to be taken in all workshops.

 

Nederman installed extraction units above all welding stations. Nederman’s flexible extraction arms enable extraction at the source, which is the most efficient solution for welding and cutting fumes and allows the students to weld in a closed environment without being exposed to harmful fumes or gases. All extraction units were connected to a welding fume extraction solution, MCP SmartFilter, with a separate fan, Combifab, in a sound enclosure.

 

The flow rate is automatically controlled by frequency control which reduces the energy consumption. The school’s grinding tables are also connected to the same frequency controlled extraction system. In addition to the welding fume extraction, Nederman was also able to supply exhaust extraction, oil mist filtration and compressed air hose reels. In the automotive workshops, where practical time is spent with students working on functioning engines, the students use exhaust extraction nozzles that are linked to the vehicles. The extraction nozzles are mounted on a 920-exhaust rail system. The oil mist in the CNC machining centre, is extracted and filtered by our NOM4 filters which were installed on each device.

 

By investing in a clean and healthy workplace for students, the Flemish government not only protects students, but creates awareness among the next generation of mechanics. Clean air in the workplace becomes more and more of a focus area and employers who take clean air seriously are becoming more attractive and will keep attracting mechanics in the future. The ones that don’t, will not survive. The future generation is conscious and will demand clean, breathable air at work.

BIOMASS

 

Valmet to Complete Biomass Boiler, Flue Gas Cleaning And Flue Gas Condensing System Works At Vilnius Combined Heat and Power Plant in Lithuania

 

Valmet has been selected in a new public procurement process as the tenderer for completing the biomass boiler, flue gas cleaning and flue gas condensing system works for Vilnius Combined Heat and Power Plant (Vilnius CHP) in Lithuania. Vilnius CHP is working on a modern heat generation capacity expansion project in the Vilnius central heating system. The new public procurement process was needed since the original contractor was unable to complete the works.

 

The order is included in Valmet’s orders received of the second quarter 2022. The total maximum value of the order is around EUR 30 million.

 

Valmet will perform a technical assessment of biomass boilers, complete the biomass boiler, flue gas cleaning and flue gas condensing system installation works, carry out commissioning works (cold and hot tests), train the power plant’s personnel and prepare the instructions for using the biomass unit.

 

After the Vilnius CHP project is completed, the power plant’s total electricity capacity will amount to 90 MW (70 MW biomass based), and the heating capacity will amount to roughly 230 MW (170 MW biomass based).

 

Since 2020, the power plant has been generating energy using municipal waste. After the biomass project is complete, energy will also be generated using biomass. The waste-to-energy unit incinerates about 160,000 tonnes of municipal waste and turn it into energy. The biomass unit will burn about 500,000 tonnes of biomass per year.

 

BIOFUEL

 

Valmet to Deliver a BioPower Heat And Power Plant And A Pretreatment BioTrac System to ORLEN Poludnie S.A. in Poland

 

Valmet will deliver key technology areas for ORLEN Poludnie’s S.A. planned second generation bioethanol (B2G) plant in Jedlicze, Poland. The engineering, procurement, and construction (EPC) delivery includes a pretreatment BioTrac system with a capacity to process approximately 400 tons of dry straw per day, a BioPower 48 MWth lignin fired combined heat and power (CHP) plant and a Valmet DNA Automation system.

The order was included in Valmet’s orders received of the first quarter 2022. The value of the order will not be disclosed. 

The plant will start its operation in 2024. Through this project ORLEN Południe S.A. will increase its share in the biofuels market. In addition, the project will support ORLEN’s ambition to reach the EU target for bio-additives in the liquid fuels market. Bioethanol will be produced from non-food agricultural feedstocks (predominantly cereal straw) sourced mainly from Polish farmers.

Ethanol process byproduct, lignin, is used as fuel in the BioPower CHP plant, producing all steam for the ethanol plant and power.

 

The delivery includes a Valmet Pretreatment BioTrac system and a Valmet BioPower heat and power plant. Both installations are controlled by a Valmet DNA automation system with embedded information management and cyber security solutions. The BioTrac pretreatment enables an annual production capacity of 25 000 tons of bioethanol.

 

Valmet BioPower plant is based on proven bubbling fluidized bed (BFB) combustion technology and flue gas cleaning combined with factory manufactured modules enabling faster project implementation, shorter site time and completion with better quality and lower implementation risks. The fuel capacity of the plant is 48 MWth.

 

ORLEN Południe S.A. is a member of the Capital Group of PKN ORLEN S.A. The business activity of ORLEN Południe focuses on the primary product segments related to the production and sales of biofuels and biocomponents, paraffin and solvents. Consistently developed technologies, emphasis on the development of know-how and a series of optimization initiatives are the foundations of the company’s development towards a bio-refinery. ORLEN is an integrated, multi-utility company operating in Central Europe and Canada. It provides energy and fuel to over 100 million Europeans, and the products are sold to over 90 countries across six continents. ORLEN is a regional leader in energy transition by implementing clean and sustainable technologies as well as power generation based on low- and zero-emission sources. Their strategic goal is to reach emission neutrality by 2050.

 

COMPANY NEWS

 

FLSmidth & Co. Group Reports Solid start to the Year With Strong Order Intake Growth of 44% in Mining

 

Group order intake increased 35% organically, driven by both Mining and Cement. Capital orders increased by 59% and service orders increased 26%. Mining order intake increased 38% organically, including four large product orders with a combined value of around DKK 1.4bn. Cement order intake increased 28% organically.

 

FLSmidth Group CEO, Mikko Keto, commented: “The first quarter of 2022 saw a strong momentum in order intake driven by both Mining and Cement. Despite the tragic war in Ukraine, activity and sentiment in the mining industry remains positive. Integration planning of the thyssenkrupp Mining business acquisition is progressing according to plan and important regulatory clearances have been received during the quarter. Our Cement business has continued its positive development on improving profitability. We saw strong organic Group revenue growth of 23%, mainly driven by Mining. Group EBITA increased by 59% compared to first quarter in 2021 despite increased inflationary pressure, supply chain challenges and negative impact from the war in Ukraine. Our key priority in this challenging time of war has been on the safety and well-being of our employees. We closely follow this tragic situation to ensure we take the right responsible decisions from a humanitarian, legal, and financial point of view”

 

Financial performance

Mining revenue grew 30% organically, driven by the higher backlog and improved market conditions compared to Q1 2021, partly offset by negative impact from the war. Mining EBITA increased by 17% to DKK 249m in Q1 2022, while the corresponding EBITA margin decreased to 7.7% from 8.8% in Q1 2021. Mining EBITA was impacted by costs related to the acquisition of thyssenkrupp’s Mining business of DKK 37m. Adjusted for these costs, the Mining EBITA margin was 8.8% in Q1 2022.

 

Cement revenue grew 10% organically. Cement EBITA continued the positive trend seen in Q4 2021, driven by higher revenue in the quarter and improvements from the executed reshaping activities in 2021. Cement EBITA amounted to DKK 53m in Q1 2022 and the corresponding EBITA margin increased to 3.6% compared to -1.7% in Q1 2021. Adjusted for a gain of DKK 23m from a sale of a property, the Cement EBITA margin was 2.0%.

 

Organic Group revenue increased 23% in Q1 2022, mainly driven Mining. Including currency effects, Group revenue increased by 27% to DKK 4,706m, driven primarily by 56% increase in capital revenue. Service revenue accounted for 56% of the total revenue during the quarter, compared to 65% in Q1 2021. Group EBITA increased by 59% to DKK 302m, as a result of the higher revenue. The corresponding Group EBITA margin increased to 6.4% from 5.1%.

The net working capital ratio increased from 6.0% in Q4 2021 to 7.3% in Q1 2022. The increase related primarily to an expected increase in inventories to mitigate the supply chain challenges and an increase in net work in progress driven by the increase in execution of capital orders. Cash flow from operating activities (CFFO) declined in line with expectations in Q1 2022, as a result of the net working capital outflow.

 

FLSmidth maintains its financial guidance for 2022. Due to the war in Ukraine, the Mining EBITA margin is expected to be in the low end of the guidance range.

 

PRODUCT NEWS

 

Parker Designs Innovative Baghouse Filter For Extreme Heat Applications

 

The Industrial Gas Filtration and Generation Division of Parker Hannifin Corporation has introduced a pleated baghouse filter for customers that collect dust in extreme heat applications. A breakthrough in filtration technology, BHA® Wicked™ High Temp Pleated Filters will operate continuously at 500°F (260°C), eliminating the need for cages saving time and money in filter installation and removal costs.

 

Cement, lime, carbon black, and other intense heat applications now have a choice with BHA Wicked High Temp Filters, a pleated filter that can operate continuously at 500°F (260°C). Baghouse operators will get all the benefits of pleated filters with this innovative filter:

 

·         Designed to eliminate bags and cages, significantly decreasing installation and removal costs

·         Reduce air-to-cloth ratios dramatically

·         Shorter filters reduce abrasion problems

·         Provides a larger dropout area

·         Increased filtration area

·         Reduce operating differential pressure

·         Promotes better airflow for increased throughput and production

·         Requires less pulse cleaning for potential energy savings

·         Provides superior filtration efficiency

 

“We are motivated by the impressive results we are achieving with Wicked High Temp Pleated Filters for our beta customers and in the lab,” said Yit-Hong Tee, lead engineer, Industrial Gas Filtration and Generation Division. “Customers are getting lower operating differential pressure - up to 50% over bags in finished filter testing and a 90% reduction in pulse-cleaning emissions compared to standard bags.”

 

For decades, baghouses in high-temperature applications have been forced to use bags and cages for dust collection. With BHA Wicked High Temp Pleated Filters, customers will get maximum benefits through increased production and reduced operational costs.

 

ENFORCEMENT ACTIONS

 

Final Allocations of Cross-State Air Pollution Rule Allowances From New Unit Set-Asides for 2021 Control Periods

 

The Environmental Protection Agency (EPA) is providing notice of the availability of data on emission allowance allocations to certain units under the Cross-State Air Pollution Rule (CSAPR) trading programs.

 

EPA has completed final calculations for the allocations of allowances from the CSAPR new unit set-asides (NUSAs) for the 2021 control periods and has posted spreadsheets containing the calculations on EPA's website. EPA has also completed calculations for allocations of the remaining 2021 NUSA allowances to existing units and has posted

spreadsheets containing those calculations on EPA's website as well.

 

The detailed unit-by-unit data and final allowance allocation calculations are set forth in Excel spreadsheets titled

``CSAPR_NUSA_2021_NOX_Annual_Final_Data_New_Units,''

``CSAPR_NUSA_2021_NOX_OS_Final_Data_New_Units,''

``CSAPR_NUSA_2021_SO2_Final_Data_New_Units,''

``CSAPR_NUSA_2021_NOX_Annual_Final_Data_Existing_Units,''

``CSAPR_NUSA_2021_NOX_OS_Final_Data_Existing_Units,'' and

``CSAPR_NUSA_2021_SO2_Final_Data_Existing_Units'',

 

available on EPA's website at https://www.epa.gov/csapr/csapr-compliance-year-2021-nusa-nodas.

 

Notice of Lodging of Proposed Consent Decree Against United States Steel

 

On May 17, 2022, the Department of Justice lodged a proposed consent decree with the United States District Court for the Western District of Pennsylvania in the lawsuit entitled United States and Allegheny County Health Department v. United States Steel Corporation,

Civil Action No. 2:22-cv-00729-CRE.

 

The United States and the Allegheny County Health Department jointly filed this lawsuit under the Clean Air Act against United States Steel Corporation, alleging violations at the Edgar Thomson steel mill in Allegheny County, Pennsylvania. The complaint seeks injunctive relief and civil penalties for exceedances of visible emissions opacity standards, as well as violations of requirements to minimize fugitive emissions, maintain and operate equipment to minimize

emissions, and comply with the facility's operations and maintenance plan.

 

The consent decree requires the defendant to perform injunctive relief to address the violations and pay a $1,500,000 civil penalty. The civil penalty will be split evenly between the United States and the Allegheny County Health Department, which will use its portion of the civil penalty to fund a multimodal trail connection for communities near the facility.

   

 

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