FGD and Acid Gas Separation Webinar June 16, 2016
Program Details
Issues and options for SO2 and other acid gas separation from coal-fired power,
cement, steel, and waste incineration plants will be the focus June 16, 2016 at
10:00 a.m. central standard time.
A collaborative format will be used to discuss decision guides on acid gas
removal for coal-fired power, cement, steel, waste-to-energy, and glass plants.
The decision guides already prepared on these subjects will be updated and
briefly displayed during the meeting. We are inviting you to provide data on any
new developments which should be incorporated. Discussion will revolve around
controversial issues such as
General
How do you determine the lowest total cost of ownership LTCO?
Can U.S. and European suppliers leverage knowledge of the LTCO to penetrate
markets in developing countries?
How does the need to remove NOx, PM, and mercury shape the decision on which
acid gas removal system should be chosen?
What efficiency improvements e.g. flue gas heat recovery are possible and how
will that shape the acid gas decision?
How do the needs differ between coal-fired power, cement, steel, and
waste-to-energy?
Dry Scrubbing
How efficient is DSI?
Where is sodium a better choice than calcium?
What improvements are achieved by using special high reactivity hydrated lime?
How widely will DSI be used in terms of which industries and which
geographies?
Is McIlvaine on the right track recommending an analysis of FIFO/LIFO to
ensure that the first sorbent on the cake is pulsed and not the fresh unreacted
sorbent?
For medium sulfur coals, can a combination of DSI and a spray drier be
competitive with circulating dry scrubbers?
How much progress is being made on using DSI solid waste and converting it
into bricks and building materials?
Should every power plant using high sulfur coal consider DSI ahead of the air
heater to reduce SO3 and to be combined with an air heater upgrade to further
reduce gas temperature?
Can DSI with ceramic catalytic filters replace all the other APC devices?
Wet Scrubbing
What about the European approach in waste-to-energy which includes two
scrubber stages including one to capture hydrogen chloride and make 30 percent
hydrochloric acid?
Why not leach out rare earths with the acid?
The Chinese are touting a technology similar to the rod deck scrubber for wet
limestone SO2 removal. How do rod decks and trays compare to spray towers in
terms of lowest total cost of ownership?
Can lime be competitive with limestone as a reagent based on lower capital
cost and higher efficiency?
Can lime or other reagents be used along with limestone?
Is the double alkali approach worth considering particularly if you have a
high magnesium lime and can make magnesium hydroxide?
Where are the ammonium sulfate and sulfuric acid options attractive?
Should powdered limestone replace ball mills (this is popular in china)
How efficient should mist eliminators be?
Components
Wet: Agitators, oxidation blowers, pumps, valves, fans, hydrocyclones are all
subject to severe service. How should these be designed to provide LTCO?
Dry: Rotary atomizers, two fluid nozzles, slakers, dust valves are all in
severe service. What selections provide the LTCO? How site specific is this in
terms of coal type and sulfur percentages?
Materials
Should linings or high alloys be used for scrubber shells? How dependent is
this on lining skills and site specific conditions
Where should weld overlays and hard coatings be applied to pumps and valves?
Consumables
What is the quality and availability of lime and limestone in each country?
Should membrane or nonwoven bags be selected?
What is the role of treatment chemicals in the fuel, flue gas and wastewater?
Click here for more information and to register
Complex Unintended Consequences Obscure the Path Forward for Air Pollution
Control
A small Ohio town no longer exists thanks to the unintended consequences of air
pollution control. A nearby power plant spent hundreds of millions of dollars to
reduce NOx. The catalyst not only reduced the NOx it converted SO2 to sulfuric
acid. Within a few days, the acid deposition did such great damage to the
buildings in the town that the utility agreed to buy the complete town and pay
for relocations. In the ensuing decade, catalyst suppliers have redesigned their
product to eliminate this problem.
New mercury regulations have such low emission limits that the instrument just
to measure gaseous mercury can cost hundreds of thousands of dollars. Prior to
issuing the regulation, EPA tested a number of stacks and found that all the
mercury existed in gaseous form. Therefore, the regulations only required
measurement of gaseous mercury. In response to the regulation requirements,
power plants, cement plants and waste-to-energy plants embraced a two-step
solution.
Step one was to convert the gaseous mercury to particulate mercury. Step two was
to remove the particulate mercury. The end result is that if step one is very
efficient and step two is not, there is lots of particulate mercury being
emitted. Another unintended consequence is that particulate mercury will not
travel far, whereas gaseous mercury can transverse the globe. Even though this
problem has been evident for a few years, there is still no proposed change in
the regulations.
The recent regulation of many pollutants combined with new technology which
makes it possible to remove all the pollutants in one device has greatly
increased the use of fabric filters. However, there has not been a recognition
of what McIlvaine describes as The importance of FIFO vs. LIFO in Dust Cake
creation.
Direct sorbent injection (DSI) and embedded catalyst dictate a new approach to
bag cleaning. In addition to discrete particle capture, bag filters are being
tasked with:
Mercury removal
Acid gas absorption
Dioxin destruction or capture
NOx reduction
The importance of the method of bag cleaning can be illustrated by use of the
accounting approach to inventory. Two options are first in first out (FIFO) and
last in first out (LIFO). If the price paid stays the same, the choice between
the two accounting methods makes no difference. But, if the cost of recent
inventory is greatly different than the past, then the accounting method makes a
big impact on profits.
The capture of discrete particles is the equivalent of price parity. Lets say
that when you pulse a bag you are always discharging the latest particles to
arrive and the remaining cake consists of the earliest. Since the ability of a
matrix of dust particles to act as a filtration medium does not change, it does
not matter which particles remain. In fact, maintaining a somewhat permanent
layer of cake protects the fabric from wear. Also a more permanent cake provides
higher dust capture. It has been shown that on-line cleaning results in some
re-deposit of dust particles. But this is does not impact discrete particle
capture efficiency.
The new paradigm with DSI is a big price difference. The newly arrived lime
particle has the capability to absorb acid gases. The lime particle deposited
earlier is already converted to calcium sulfate and provides no additional
absorption capability. The semi-permanent cake layer is very undesirable for
acid gas capture. Mercury re-emission is also a risk for an activated carbon
cake which is semi-permanent. So it is very important to adopt FIFO and not
LIFO.
This leads to the obvious question as to which are the best cleaning methods to
achieve LIFO? The long running debate about surface filtration vs. depth
filtration needs to be reviewed in light of FIFO. Also, the pulsing method
itself needs to be reviewed. Do some methods result in more re-entrainment of
particles in the previous cake than do others? Should more of the cake be
removed with each pulsing?
It could be argued that the reaction takes place in the ductwork and not on the
bag. But the big difference in performance of bag filters vs. precipitators with
DSI proves that the cake absorption is substantial.
There may be lots of research on this subject but if so, McIlvaine would
appreciate feedback on it. If there is not, it is an area deserving lots of
attention.
Bag cleaning is also made more challenging by the increasing use of ceramic
filter elements. The advantage of these elements is the ability to remove dust
at 850°F. The older generation rigid ceramic has been replaced by ceramic fiber
media which can be pulsed. However, this media cannot necessarily be pulsed with
the identical system used for synthetic bags. An alumina refinery in Australia
was having cleaning problems with a ceramic filter. Pentair Goyen analyzed the
situation and provided a more robust pulsing system. This solved the problem.
Ceramic, glass and even synthetic media are incorporating catalyst in the media
to reduce NOx or oxidize dioxins. Do these designs require a different cleaning
approach? The catalyst in the Clear Edge design is not on the surface. So, the
dust cake will not affect performance except if it causes maldistribution of the
gas. If more gas flows through one area than another, the reactivity of the
system is reduced.
A broader subject is the whole approach to cleaning. High pressure/low volume is
the most popular option. Does capture of these other pollutants open the door
for high volume /medium pressure or even for reverse air cleaning?
The potential for the one-stop shopping is great. Costs of pollution control can
be reduced for new installations. The small footprint makes a big difference in
the cost of upgrading existing plants to meet new air pollution rules. It is,
therefore, important to understand and then maximize FIFO potential. McIlvaine
will be interviewing experts in the various niches to shed more light on this.
The results will be published in:
1ABC Fabric Filter
3ABC FGD and DeNOx Knowledge Systems
44I Power Plant Air Quality Decisions (Power Plant Decisions Orchard)
Industrial Air Plants and Projects
For information on how to participate contact: Bob McIlvaine at 847-784-0012
ext. 112 rmcilvaine@mcilvainecompany.com.
Utility E-Alert Tracks Billions of Dollars of New Coal-fired Power Plants on a
Weekly Basis May 27, 2016
Here are some headlines from the Utility E-Alert.
UTILITY E-ALERT
#1273 May 27, 2016
Table of Contents
COAL WORLD
First 800 MW Supercritical Thermal Power Plant in Karnataka, India
Commissioned
EPH bids for Rybnik Coal-fired Power Plant in Poland
Doosan Babcock wins Contract for Biomass Conversion of Coal-fired Power Plant
in UK
Egyptian Power Plant orders 27 KSB Pumps
The 41F Utility E-Alert is issued weekly and covers the coal-fired projects,
regulations and other information important to the suppliers. It is $950/yr. but
is included in the $3020 42EI Utility Tracking System which has data on every
plant and project plus networking directories and many other features.
HOT TOPIC HOUR (HTH) SCHEDULE
DATE HOT TOPIC HOUR AND DECISION GUIDE SCHEDULE
The opportunity to interact on important issues
June 16, 2016
Decisions FGD and Acid Gas Separation - Issue and options for SO2 and other acid
gas separation from coal-fired power, cement, steel, and waste incineration
plants.
Click here for more information and to register
TBA
Decision Guide LIFO vs FIFO filter pulsing to maximize acid gas capture - Last
sorbent on the cake is first removed. How do we change that to FIFO?
Click here to participate in the preliminary analysis
TBA
Decision Guide Molecular Sieve Switching Valves - Which of three designs is best
under each of the varying conditions found? What materials and coatings are
needed?
Click here to participate in the preliminary analysis
TBA
Decision Guide Choke Valves - What designs work best given the sand, water,
pressures and other challenges for surface and sub surface applications?
Click here to participate in the preliminary analysis
July 14, 2016
Markets Desalination -Thermal vs. Membrane; energy recovery, pump, valve,
compressor and chemicals options; power/desalination combinations.
August 18, 2016
Markets Oil, Gas, Refining - Supply and demand; impact on flow control and
treatment products; regional impacts e.g. subsea in North Atlantic vs. shale in
the US vs. Oil Sands in Canada.
TBA
Markets Food - Analysis of 12 separate applications within food and beverage
with analysis of valve, pump, compressor, filter, analyzer and chemical options;
impact of new technologies such as forward osmosis.
TBA
Markets Municipal Wastewater - Quality of pumps, valves, filters, and analyzers
in Chinese and Asian plants; new pollutant challenges; water purification for
reuse.
TBA
Markets Mobile Emissions -Reduction in CO, VOCs, and particulate in fuels, oils,
and air used in on and off road vehicles; impact of RDE and failure of NOx traps
and the crisis in Europe created by the focus on clean diesel.
Click here to Register for the Webinars
FGD and Acid Gas Separation - Issue and options for SO2 and other acid gas
separation from coal fired power, cement, steel, and waste incineration plants.
Click Here to Register
This free webinar will be held at 10:00 a.m. on June 16. A collaborative format
will be used to discuss decision guides on acid gas removal for coal fired
power, cement, steel, waste to energy, and glass plants. The decision guides
already prepared on these subjects will be updated and quickly displayed during
the meeting. Discussion will revolve around controversial issues. Subscribers to
Power Plant Air Quality Decisions and Industrial Air Plants and Projects can
access the guides at any time. End users also have access upon request.
Information on new developments is continually solicited. For questions contact
Bob Mcilvaine at rmcilvaine@mcilvainecompany.com 847-784-0012 ext. 112. To
register click here
LIFO vs. FIFO filter pulsing to maximize acid gas capture - Last sorbent on the
cake is first removed. How do we change that to FIFO? Click here to participate
in the preliminary analysis.
Direct Sorbent injection is becoming increasingly popular. Much of the acid gas
is removed on the cake formed in the pulse jet filter. It is critical that the
unreacted or last in sorbent is not the first out. The LIFO vs FIFO accounting
concept may apply. Input on this subject is solicited from sorbent, dust
collector, bag and valve suppliers. Over the next few months we will assemble an
analysis and decision guide on maximizing acid gas capture in the bag filter. A
webinar will be scheduled for early Fall to discuss the findings. For more
information contact Bob McIlvaine at rmcilvaine@mcilvainecompany.com
847-784-0012 ext. 112
Molecular Sieve Switching Valves
Molecular sieves are used to dehydrate gas. The valves used in switching from
one sieve bed to another are subject to severe service including zeolite
particles and corrosive, hot conditions. There is considerable controversy on
the best valve designs and materials choices. Over the next few months we will
assemble an analysis and decision guide on this subject. The preliminary
analysis is provided at Severe Service Valve Technologies and Markets. A webinar
will be scheduled for early Fall to discuss the findings. For more information
contact Bob McIlvaine at rmcilvaine@mcilvainecompany.com 847-784-0012 ext. 112
Choke Valve Decision Guide and Webinar
McIlvaine is compiling a continually updated Decision Guide for operators of
choke valves used in oil and gas and other industries for fluid control.
Contaminants such as sand integrated into varying mixtures of water, oil,
methane and other gases provide both operational and maintenance challenges. The
guide will identify the major applications and then the performance of various
designs and various materials for specific conditions. The Guide will be the
basis of a recorded discussion to be conducted in early fall 2016. The guide
will be offered free of cost to any end user. It will also be published in
Industrial Valves: World Markets and Strategies. The wisdom of the industry is
sought in order to make this guide the best it can be. Input is welcomed from
any and all sources. White papers, articles and other data to further the
discussion would be most helpful. The background information and part of the
analysis has been prepared and is displayed at Choke Valve Decision Guide. For
more information contact Bob McIlvaine at rmcilvaine@mcilvainecompany.com847
784-0012 ext. 112
Details on Webinars
McIlvaine conducts periodic webinars which are in a discussion format and are
free of charge to all participants. The displayed material and recordings are
free to purchasers of the products and services and by subscription to others.
Format: 50-90 minute recorded discussion using Mcilvaine display material. The
session will be free of charge to all participants but registration is required.
Approach: There are two types of webinars. One is focused on Markets and
directed to suppliers. The other is focused on aiding purchasers make the best
Decisions relative to purchases of flow control and treatment equipment and
services.
Markets HTH
General overviews of the market including size and major variables will be
discussed with heavy emphasis on technology and regulatory drivers. The
presentation will be based on the latest information appearing in Mcilvaine
multi-client reports. Questions and views from both subscribers and
non-subscribers are encouraged.
Decisions HTH
Mcilvaine has been publishing information systems on pollution control since
1974. Each subject is organized by the pollutant control technology e.g. fabric
filter, scrubber etc. There are search capabilities to retrieve information on
any application. The newest addition has been slide deck systems displaying the
issues and options relative to a specific applications. Coal-fired power,
cement, steel, and waste combustion decision slide decks are continually
updated.
The continually updated slide decks are displayed on the applicable Decision
System. It is recommended that participants view the slide deck in advance of
the session and be prepared with questions and views.
Value to purchasers and specifiers: Your questions and interests will be
prioritized in the discussion. You will get a monthly newsletter and have
continuing access to the system and multiple ways to interface in the future
along with a networking directory of suppliers.
Value to Suppliers: You have the opportunity to provide data to be considered at
no charge. If you are also a subscriber you will see the summaries in advance
and be able to shed light on issues and options not properly covered in the
slide deck. If you are a subscriber you will receive the monthly newsletter and
continuing yearly access to the system including networking directories.
44I Power Plant Air Quality Decisions includes 1ABC, 3ABC, 4ABC, 9ABC decision
services but not 2ABC. So those with multiple technologies and at least partial
focus on power will find this combination most cost effective.
Applicable Services for Hot Topic Hours**
Pollutant
Industry Fabric Filter
(1ABC) Scrubber
(2ABC) Precipitator
(4ABC) FGD & DeNOx
(3ABC) Air Pollution
Monitoring
(9ABC) Gas
Turbine
Decisions
FGD and Acid Gas
June 16, 2016 Coal X X
Sewage X X
WTE X X
Cement X X
Steel X X
*Included in custom system
** Many of the decision guides also are displayed in the relevant market
reports. Power Plant Air Quality Decisions includes 1ABC, 3ABC, 4ABC, 9ABC
___________________________________________________________________________
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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