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.
Air and Water Monitoring Market to grow to $28 Billion Next Year
In 2017 sales of water monitoring equipment and services will be $17 billion and
air monitoring services will be $11 billion. This is the latest forecast in N031
Air and Water Monitoring: World Market.
Asia will be the leading region followed by the Americas. Chinese sales will be
over $4 billion representing one-third of the entire Asian market.
Thermo Fisher has been in the Chinese air pollution monitoring business for
decades. By one definition it is said to have a 70 percent market share of
ambient air monitors used in Chinese cities. It sold its first mercury monitor
in China more than ten years ago. The Thermo decision to locate its air
pollution research center in China is testimony to confidence in its ability to
protect intellectual property in the country.
The monitoring business is a small part of the total Thermo business but has
contributed to the 10 percent annual increase in revenue over the last five
years. The EPS CAGR is an impressive 17 percent. Revenue growth has been 28
percent per year in China with sales of $1.4 billion last year.
The ambient market is growing fastest in developing countries where governments
are investing in networks. However, in the U.S. there is a significant market
for ambient networks purchased by power plants and industrial facilities which
have to address new federal standards as well as embryonic standards in various
states.
For more information on N031 Air and Water Monitoring: World Market, click on:
http://home.mcilvainecompany.com/index.php/markets/2-uncategorised/106-n031.
Utility E-Alert Tracks Billions of Dollars of New Coal-fired Power Plants on a
Weekly Basis
Here are some headlines from the Utility E-Alert.
UTILITY E-ALERT
#1271 May 6, 2016
Table of Contents
POWDER BULK SOLIDS SHOW
More Focus on Products for Coal-fired Power
The importance of FIFO vs. LIFO in Dust Cake
Valve Displays were Impressive
COAL US
OG&E receives approval for Dry Scrubber at Sooner Coal-fired Power Plant
Dynegy to shut down Multiple Central and Southern Illinois Coal-Fueled Units
COAL WORLD
Malaysia Commissions 1-GW Ultra-supercritical Coal-fired Power Plant
Chinese firm to restart Myanmars Tigyit Coal-fired Power Plant
Turkey to introduce Incentives, Environmental Exemptions for Coal-fired Power
Plants
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.
McIlvaine Hot Topic Hours (HTH) and Recordings
Explanation Applicable Services Schedule & Registration Sponsored 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
The 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
Mercury
February
11, 2016 Coal X X
WTE X X X
Sewage X X X
Cement X X
Natural Gas*
DeNOx
March 24, 2016 Coal X X
Incineration X X
Steel X X
Cement X X
Diesel*
Gas Turbine X X
Hot Gas
Filtration Coal X X X X
WTE X X X X
Cement X X X X
Steel X X X X
Incineration X X X X
Coal Gas X X X
GT Intake X
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
HOT TOPIC HOUR (HTH) SCHEDULE
Dates for the next 6 meetings are firm; the others will be held in sequence at
approximately two week intervals. Unforeseen developments could dictate the
insertion of new subjects.
DATE SUBJECT
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 to Register
TBA
Markets Desalination - Thermal vs. Membrane; energy recovery, pump, valve,
compressor and chemicals options; power/desalination combinations.
TBA
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 diesels.
Click here to Register for the Webinars
Sponsored Webinars allow suppliers to take advantage of all the valuable
information on their power point presentations. Click here for details
Hot Topic Hour Recordings
See and hear recordings of past Hot Topic Hours (Free for subscribers, $95.00
for non-subscribers)
Chronological
Order Now!
Free Sponsored Webinars
Albemarle - Cement MACT
AMC Power
Aquatech
GE - Mercury Capture
Honeywell
NVISTA
Midwesco - Bagfilter Performance Analyzer
Neundorfer
Pavilion
Sick Maihak - Cement MACT
Tekran Instruments - Cement MACT
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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