Power Plants Need to Think Outside the Box in Dealing with Obsolescence
The semiconductor industry has been reinventing itself continually. Moore’s law
predicted that the number of transistors per square inch on integrated circuits
had doubled every year since the integrated circuit was invented and would
continue to do so. The opposite is true for coal-fired boiler power plants in
the U.S. Most were built between 1950-1980 and are no more efficient now than
when they were installed. Whereas the Chinese assume an economic life for a
coal-fired power plant of 25 years, the U.S. tends to act as if the economic
life is 50 years or more.
Most of the blame for this lack of progress falls on the regulators but some is
also due to the philosophy of the operators. They have not been able to think
outside the box. The focus has been on power generation rather than supply of
useful products. A common attitude is “we are not a chemical plant and do not
want to be in the chemical business.” The steam plumes emanating from cooling
towers and stacks are a combination of wasted heat and water which could be used
by co-generating partners. Power plants should think outside the box and
consider a product mix which includes:
• Electricity
• Steam
• Chemicals
• Building materials
• Tipping fees for disposal of solid biomass waste from municipal and other
sources.
Steam: There is an initiative to reduce coal-fired power plant CO2 emissions by
30 percent over the next several decades. This can be achieved by shutting down
30 percent of the capacity or it can be achieved through cogeneration. Great
Rivers Energy has demonstrated that by building the Blue Flint Ethanol plant
on-site and through the new Spiritwood plant that it can achieve the 30 percent
reduction in greenhouse gases for the combined power and cogeneration sources.
A new hot gas filtration technology produces clean gas at 850oF. This will
reduce parasitic energy for air pollution control and also allow efficient
extraction of the heat in the flue gas. Industrial power plants have embraced
this new technology but the power industry has not.
Chemicals: Last week McIlvaine observed that two technologies (leaching rare
earths from flyash with hydrochloric acid and two-stage scrubbing producing
hydrochloric acid and gypsum) can be combined to supply a very economical route
for the U.S. to be self-sufficient in rare earth production. Other options
include fertilizers such as ammonium sulfate and various forms of sulfur.
Powders: Many power plants already produce gypsum used in wallboards. However,
there are products with higher revenue potential. Finely, ground pure gypsum can
replace precipitated calcium carbonate for paper coatings in magazines and other
glossy publications. Rather than produce gypsum, power plants can produce a
chemically fixed landfill product which encapsulates toxics and reduces
expenditures for wastewater treatment.
Solid waste tipping fees: New combustion techniques to gasify municipal solid
waste offer a way for utilities to generate revenues from tipping fees, reduce
coal consumption and reduce NOx by introducing the gasified waste as a reburn
fuel above the primary firing zone. Since air pollution systems on coal-fired
power plants must already remove air toxics, there would not be any additional
pollution control capital expense.
McIlvaine is presenting these options with a series of initiatives including:
• Weekly webinars: Hot Topic Hour Schedule and Recordings
• Free websites: Continuous Analyses
• Free knowledge systems for power plant operators: Power Plant Systems and
Components
• Subscription services for suppliers: Power Plant Air Quality Decisions,
Utility Tracking System, Chinese Utility Plans and Utility People
• Market reports: FGD World Markets, Utility Mercury Air Reduction Markets,
Fossil & Nuclear Power Generation: World Analysis & Forecast and Fabric Filter
World Markets
Renewable Energy Briefs 03 04 15
Block Island Wind Farm Now Fully Financed
Deepwater Wind Block Island, a wholly-owned subsidiary of Deepwater Wind, has
fully financed the Block Island Wind Farm, reaching financial close on more than
$290 million in project financing provided by Mandated Lead Arrangers Societe
Generale of Paris, France, and KeyBank National Association of Cleveland, OH.
With these major agreements, Deepwater Wind has now secured all debt and equity
funding needed to construct and operate its 30-megawatt Block Island Wind Farm –
already under construction.
Deepwater Wind is the only United States offshore wind company to reach this
critical milestone. The Block Island Wind Farm will be America’s first offshore
wind farm.
One of the World’s Largest Solar Projects Starts Commercial Operation
U.S. Secretary of Interior Sally Jewell along with about 150 federal, state and
local officials, and energy industry leaders, gathered February 9, 2015 to
commission the 550-megawatt (MW) Desert Sunlight Solar Farm, located in Desert
Center, Riverside County, CA.
Project owners NextEra Energy Resources, LLC, a subsidiary of NextEra Energy; GE
Energy Financial Services, a unit of GE; and Sumitomo Corporation of Americas
all helped flip the switch for the official commissioning of Desert Sunlight.
The Desert Sunlight Solar Farm is located on approximately 3,600 acres of land
managed by the U.S. Bureau of Land Management in Riverside County.
First Solar permitted, constructed and is now operating the plant, which uses
over 8 million First Solar modules. The power generated is being provided to
Pacific Gas & Electric Company and Southern California Edison both under
long-term contracts.
Mainstream Renewable Power Launches $1.9 Billion Pan-African Renewable Energy
Platform
Global wind and solar company Mainstream Renewable Power has announced the
launch of a pan-African renewable energy generation platform, Lekela Power,
which it has formed along with Actis, the global pan-emerging market private
equity firm. Lekela Power will provide between 700 and 900 megawatts of wind and
solar power across Africa by 2018.
Mainstream announced financial close and the start of construction for three
wind farms in South Africa which will form the core of the Lekela platform. The
projects, which have a combined capacity of 360 MW, are located in the country’s
Northern Cape and were awarded to Mainstream as part of the Government’s
Renewable Energy Procurement Program. They are expected to reach commercial
operation beginning in 2016. Mainstream also has a pipeline of other projects
across Africa which will transfer to the Lekela platform at financial close
including the 225 megawatt Ayitepa wind project in Ghana.
Southern Company Subsidiary Acquires Two Georgia Solar Projects Totaling 99 MW
Southern Company subsidiary Southern Power announced the acquisition of two
photovoltaic (PV) solar projects totaling 99 megawatts (MW) in Georgia – the
80-MW Decatur Parkway Solar Project and the 19-MW Decatur County Solar Project –
from Tradewind Energy, Inc.
The projects were proposed by Tradewind Energy, Inc. and selected by Southern
Company subsidiary Georgia Power in a competitive process through the nationally
recognized Georgia Power Advanced Solar Initiative.
The electricity and associated renewable energy credits (RECs) generated by the
80-MW facility will be sold under a 25-year power purchase agreement (PPA) with
Georgia Power. Construction of the 80-MW facility is currently scheduled to
begin in March.
Georgia Power will purchase the energy generated from the 19-MW project under a
20-year PPA. Southern Power will retain the associated RECs, which it may sell
to third parties. Construction of the 19-MW facility is currently scheduled to
begin in June.
The projects, which are expected to enter commercial operation in late 2015,
will be constructed on separate sites totaling approximately 950 acres in South
Georgia's Decatur County using single-axis tracking technology – optimizing
efficiency by directing solar panels to track the sun.
Saft’s Energy Storage System to be at Heart of Project on Grid Integration of
Variable Renewable Energies on Remote Japanese Island
Saft has been awarded its first energy storage system (ESS) contract in Japan to
supply a containerized lithium-ion (Li-ion) battery system for a remote island
microgrid project conducted by Takaoka Toko Co., Ltd. – a subsidiary of Tokyo
Electric Power Company (TEPCO). The demonstration project on NiiJima Island will
comprise diesel generators, solar panels and wind power installations working in
various combinations to optimize the usage of renewable energy resources.
The Japanese government is leading the way in the development of renewable
energy in order to reduce the country’s dependency on fossil and nuclear based
energy generation. This has resulted in the setting of targets to increase the
proportion of electricity to be generated from renewable sources from the
current 10 percent to 13.5 percent (approximately 141 billion kWh) in 2020 and
20 percent by 2030. For an experimental period of 5 years, this project has as
its principal objective to highlight the technical challenges (such as expected
electric power quality and grid management) that need addressing when renewable
energies – especially wind generation – are associated with electric power
systems and to study the related solutions.
Niijima is a volcanic island in the Philippine Sea, South-East from Tokyo at
about two and a half-hours by jet boat. Its small area and population of around
3,000 people is the perfect location for this demonstration project as a
miniature model of Japan in anticipation for 2030.
For more information on Renewable Energy Projects and Update please visit
http://www.mcilvainecompany.com/brochures/Renewable_Energy_Projects_Brochure/renewable_energy_projects_brochure.htm
Headlines for Utility E-Alert –February 27, 2015
UTILITY E-ALERT
#1212– February 27, 2015
Table of Contents
COAL – US
• PUCO rejects Deal to have Ratepayers subsidize a Coal-fired Power Plant
COAL – WORLD
• ECC released for Power Plant in Cadiz, Philippines
• Siemens upgrades I&C System of GE Steam Turbines in South Korea
• OPGS Power's 300 MW Coal-based Power Plant Ready
GAS/OIL – US
• Siemens to supply Gas Turbines for Holland, MI Combined Cycle Power Plant
• Toshiba Steam Generator in Operation at Kemper IGCC Power Plant
• El Paso nears completion of First Two 88 MW Gas-fired Units at Montana Power
Plant
• Proposed Natural Gas-fired Power Plant in Texas moves forward
GAS/OIL – WORLD
• Scottish Parliament Members to call for New Gas-fired Power Station at
Longannet, Fife
• Wärtsilä signs Contract with Shanghai Electric for Emission Reductions to
Maltese Power Plant
• Alfa Laval wins Order to supply Compact Heat Exchangers to Middle East Power
Plant
NUCLEAR
• Construction of Belarusian Nuclear Power Plants on Schedule
• Kudankulam Nuclear Units 2 and 3 to break Ground in 2015-16
• GDF Suez wants Areva to deliver Nuclear Reactors
BUSINESS
• European Commission opens an in-depth probe of GE's takeover of Alstom's Power
Division
• AFS and Filtration News join McIlvaine in creating a New Route to Market for
You
• Major Shifts in the Market for Thermal Treatment of Stack Gases
HOT TOPIC HOUR
• Mercury Hot Topic Hour February 26 explores Ways to optimize Performance
• “Mercury Measurement and Capture” Hot Topic Hour continues on March 5th, 2015
• Upcoming Hot Topic Hours
For more information on the Utility Tracking System, click on:
http://home.mcilvainecompany.com/index.php/databases/2-uncategorised/89-42ei
“Power Plant Wastewater Treatment Options and Obstacles Expand” – “Hot Topic
Hour” March 12, 2015
New effluent guidelines will require investments by utilities to discharge
cleaner wastewater. The air toxic rules are causing airborne metals to be
captured in scrubbers. This results in the need to remove selenium, mercury and
other toxics from the wastewater discharges.
The difficulty and time to obtain a discharge permit is leading many GTCC plant
builders to invest in zero liquid discharge systems. They may also utilize
treated municipal wastewater. New solid waste rules will eliminate power plant
ash ponds.
McIlvaine is addressing all the options and obstacles in “Power Plant Systems
and Components.” A series of webinars on power plant water and wastewater are
being recorded and included in the service. Live discussions are enhanced by
questions and comments from participants. So join us on March 12 and hear the
following presenters:
Jeffrey Tate, President, Agape Water Solutions
Brian M. Clarke, P.E., Water Treatment Project Manager, Kiewit Engineering &
Design Co.
Barbara Carney, Chemical Engineer, Department of Energy, National Energy
Technology Laboratory
Caroline Dale, Principal Engineer - Biological Processes, WATER TECHNOLOGIES,
Veolia Water North America
Click here for the Subscriber and Power Plant or Cement Plant Owner/Operator
Registration Form
Click here for the Non-Subscribers Registration Form
NOx Control Options Analyzed By Q & A in March 26, 2015 “Hot Topic Hour”
There are a number of new technologies which increase the options available for
NOx reduction. All of these are already analyzed on the Power Plant Air Quality
Decisions website. This website is free of charge to all power plants around the
world. This means that the utility participants can enter this discussion
pre-armed with the claimed benefits of alternative choices. They can ask
questions as can the A/Es and suppliers to clarify the performance and cost of
the choices as they apply to the unique site specific needs of the individual
power plants. Advocates of the various technologies will be available to answer
questions posed by the utilities and by the host.
There are lots of good conferences where you can listen to the speakers but you
only have a few minutes for discussion. At EUEC, Frank Fitch of Linde laid out
the advantages of using ozone ahead of scrubbers. How does this compare to SCR
or SNCR on a cost basis for a specific plant with unique plant layout and NOx
generation aspects? Can this technology be used as a trim technology?
Martin Schroter of Dürr will give a presentation on ceramic catalytic filters
with DSI in the McIlvaine Dry Scrubbing webinar on March 19. Can the catalytic
filter deliver the efficiency needed by specific utilities? Could it be used
prior to the LoTOx? What about SNCR in combination with both?
Haldor Topsoe and FLS are launching two versions of catalytic filters, one for
450oF and another for 850oF. How should they be evaluated?
There are lots of ways that hybrid systems can combine for optimum results.
These have been covered in our November 6 webinar (see summaries below).
There are also lots of analyses of ways to minimize SCR costs including
strategic replacement of catalyst layers and catalyst regeneration.
A range of issues will be discussed. Here are some of the past presentations:
Innovation - Co-coupling of SCR & SNCR by Mark Ehrnschwender, STEAG Energy
Services - Hot Topic Hour November 6, 2014
Mark covered a number of innovations developed by this unique organization which
operates power plants, provides engineering and also provides services such as
catalyst renovation.
Revision Date: 11/6/2014
Tags: 221112 - Fossil Fuel 化石燃料, STEAG Energy Services, SCR, SNCR, Catalyst
Maintenance, Germany
________________________________________
Hybrid DeNOx by George Grgich, LP Amina - Hot Topic Hour November 6, 2014
George discussed cost effective NOx reduction solutions for small and medium
sized boilers.
Revision Date: 11/6/2014
Tags: 221112 - Fossil Fuel 化石燃料, LP Amina, SCR, SNCR, Burner, China
________________________________________
Advanced Layered Technology Approach (ALTA) for NOx Reduction by Marc Cremer,
Reaction Engineering International - Hot Topic Hour November 6, 2014
Marc showed data to support the claim that advances in furnace controls can be
more economically attractive than SCR for some power plants.
Revision Date: 11/6/2014
Tags: 221112 - Fossil Fuel 化石燃料, Reaction Engineering International, SCR, SNCR
________________________________________
Coal-fired Power Plant NOx Reduction Innovations Webinar - Hot Topic Hour
November 6, 2014
Work by EPRI and Reaction Engineering in the U.S., Steag in Europe and LP Amina
in China underlined the international nature of research and progress in NOx
control. All three presenters talked about ways to combine NOx control
technologies in the furnace and the back end of the system in order to maximize
cost effectiveness of NOx control.
Revision Date: 11/6/2014
Tags: 221112 - Fossil Fuel 化石燃料, STEAG Energy Services, Reaction Engineering
International, LP Amina, SCR, SNCR, Catalyst Maintenance, Burner, China, Germany
Lafarge Mannersdorf installs a hot ESP and SCR
This plant installed a hot ESP to reduce the dust loading to a new SCR to 2
g/m3. This allowed selection of a relatively small amount of catalyst with
narrow openings. This decision was made as an alternative of reheating gas and
then locating the SCR at the tail end of the process. This unit has been
installed since 2012 and is reported to be operating with some problems
according to Bernhard Kopf of Lafarge. The problem is that the ESP is not
meeting the predicted emission limits and is running much higher and, therefore,
the catalyst requires periodic cleaning. However, deactivation has been
negligible.
Revision Date: 4/16/2014
Tags: Lafarge North America, Ceram Environmental, SCR, Precipitator
________________________________________
Measuring Ammonia Slip from Post Combustion NOx Reduction Systems
In many facilities there may be room for process improvement that could reduce
operating costs or provide revenue enhancement opportunities. Operating SNCR or
SCR technology closer to its limit offers these benefits but increases the risk
of high ammonia slip. The risk could be abated with the use of ammonia
monitoring technology. But, except for gas-fired plants, continuous ammonia slip
monitoring technologies have not been available at a practical price to
facilitate these cost-saving or revenue enhancing improvements. Conditions that
exist in high dust, high temperature, high NOx and/or high SO2 environments make
most analyzer methods of continuously measuring ammonia unsuitable for
application to coal-fired power plants. An overview of the technologies
available for measuring ammonia in the high dust region downstream of a NOx
reduction system and the status of their development is provided.
Revision Date: 4/14/2014
Tags: 221112 - Fossil Fuel 化石燃料, 221112 - Fossil Fuel 化石燃料, Andover Technology
Partners, SNCR, Ammonia, Tunable Diode Laser Spectroscopy, Continuous Emissions
Monitor, SCR
________________________________________
Fuel Tech has New HCl Treatment Chemical and provides SCR Straighteners at La
Cygne by Reid Thomas, Fuel Tech - EUEC Conference 2014 - Hot Topic Hour April
10, 2014
Straightening the flow at KCP&L LaCygne Unit 1 has provided uniform flow in the
SCR hood to prevent flyash accumulation. This results in reduced catalyst
replacement costs and reduced vacuum removal costs for deposits, according to
Reid Thomas.
Revision Date: 4/8/2014
Tags: 221112 - Fossil Fuel 化石燃料, Fuel Tech, Mercury, Chemical, SCR, Mercury
Removal
________________________________________
SCR Technology for NOx Control
Due to strict NOx emission limits, the Mellach Combined Cycle Power Station in
Austria installed two SCRs integrated into the HRSGs. This presentation provides
a case study of the installation and provides information about Europe’s
emission limits for combined cycle power plants.
Revision Date: 4/4/2014
Tags: 221112 - Fossil Fuel 化石燃料, Andritz, Verbund Thermal Power, SCR, Ammonia
Injection Grid, Catalyst, Regulation, Policies, Air Pollution Control
________________________________________
How to Reduce Catalyst Lifecycle Cost, Improve Reliability
Balancing the requirements of each SCR system in the fleet can be challenging. A
system can reduce NOx by greater than 95 percent, but, when the efficiency of
the SCR is pushed beyond 85 percent and—or, if—the outlet emissions are less
than 5 ppm, the system becomes much more sensitive to several independent system
parameters. These include overall catalytic potential, effective ammonia
injection/mixing in the flue-gas stream, flue-gas characteristics for inlet NOx,
velocity, and temperature distributions. Issues can be addressed by
high-efficiency SCR designs with system modeling, flow correction devices,
enhanced catalyst volumes, and a robust ammonia injection grid design.
Revision Date: 10/23/2013
Tags: 221112 - Fossil Fuel 化石燃料, Cormetech, Catalyst, SCR, Air Pollution
Control, Combined Cycle Journal
McIlvaine Hot Topic Hour Registration
On Thursdays at 10:00 a.m. Central time, McIlvaine hosts a 90 minute web meeting
on important energy and pollution control subjects. These Webinars are free of
charge to owner/operators of the plants. They are also free to McIlvaine
Subscribers of Power Plant Air Quality Decisions and Utility Tracking System.
The cost for others is $300.00 per webinar.
See below for information on upcoming Hot Topic Hours. We welcome your input
relative to suggested additions.
DATE SUBJECT DESCRIPTION
March 12, 2015 Power Plant Wastewater Treatment More Information
March 19, 2015 Dry Scrubbing and DSI More Information
March 26, 2015 NOx (SCR, SNCR)
Click here for the Subscriber and Power Plant or Cement Plant Owner/Operator
Registration Form
Click here for the Non-Subscribers Registration Form
----------
You can register for our free McIlvaine Newsletters at:
http://home.mcilvainecompany.com/index.php?option=com_rsform&formId=5
Bob McIlvaine
President
847-784-0012 ext 112
rmcilvaine@mcilvainecompany.com
www.mcilvainecompany.com