Large Individual Projects and Multiple Small Projects by Large Treatment Plants
make Sales easier for Suppliers to North American Municipal Wastewater Plants
Ten percent of North America’s 20,000 wastewater plants buy the majority of the
flow control and treatment equipment purchased by wastewater treatment plants in
North America. Their large expansions and upgrades account for a majority of
capital expenditures. This allows the supplier to identify his prospects months
or years in advance of the actual sale. If the supplier is relying on quality
rather than price to sell his product, then the opportunity to shape the final
decision well in advance is critical.
An example of a large project is The Lions Gate Wastewater Treatment Plant in
Vancouver. It has been told by the federal government it must upgrade to
secondary treatment by December 31, 2020. The plant is one of two remaining
primary treatment plants in the region. New federal regulations require all
primary treatment plants be upgraded to secondary treatment. The cost will
exceed $2 billion. So this is a project which will involve contacts with the
city and A/E over the next two years in order to maximize order potential.
Some smaller projects are predictable long in advance due to new regulations or
outdated technology. Plants with lagoons for sludge dewatering are likely to be
considering changes. The City of Alliance, Ohio plans to build a dewatering
system. Its lagoons are full. Over the20 year life of a new plant there is
economic justification for this investment. It is good to be alerted to specific
projects but, if you are selling dewatering equipment, you should be calling on
every plant with lagoons and every plant with 20 year old dewatering equipment.
One way to make sure that you thoroughly pursue the large opportunities is to
single out the largest prospects in each state. Here is a sample for Colorado:
Numeric by Flow
Rate (MGD) |
Plant Name |
40 |
Aqua Nueva Wastewater Treatment
Plant |
30 |
Pima County Wastewater Treatment
Plant |
17.5 |
Tolleson, City Of |
14.74 |
Nogales International Wastewater
Treatment Plant |
102.24 |
Total |
You can determine the market share for these plants as follows:
Wastewater Industry - Percent of
U. S. Market by State |
|
|
||||
STATE |
2015 |
2016 |
2017 |
2018 |
2019 |
2020 |
Alaska |
0.24 |
0.24 |
0.25 |
0.25 |
0.25 |
0.26 |
California |
12.20 |
12.42 |
12.65 |
12.87 |
13.11 |
13.34 |
Hawaii |
0.43 |
0.44 |
0.44 |
0.44 |
0.44 |
0.45 |
Oregon |
1.26 |
1.28 |
1.30 |
1.33 |
1.35 |
1.38 |
Washington |
2.21 |
2.25 |
2.29 |
2.34 |
2.38 |
2.42 |
TOTAL Pacific States |
16.35 |
16.64 |
16.93 |
17.23 |
17.53 |
17.84 |
Arizona |
2.13 |
2.16 |
2.20 |
2.24 |
2.28 |
2.32 |
Colorado |
1.71 |
1.74 |
1.77 |
1.80 |
1.83 |
1.87 |
Idaho |
|
|
|
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|
In 2017, Colorado’s secondary municipal wastewater capacity will be 1.77 percent
of the total 40,000 mgd for the U.S. The top four plants have a total of over
100 mgd capacity which is 14.7 percent of the 680 mgd for the entire state.
For more information on a system to identify all plants and projects, click on:
62EI North American Municipal Wastewater Treatment
Facilities and People Database
For more information on the program to reach these prospects, click on:
Detailed Forecasting of Markets, Prospects and Projects
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. Let’s 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:
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 rmcilvaine@mcilvainecompany.com
Here are some Headlines from the
Utility E-Alert
UTILITY E-ALERT
#1274 – May 27, 2016
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.
Flow Control and Treatment Component Solutions provide a $500 Billion Market
The market for components used in flow control and treatment will be $395
billion in 2017. However, component suppliers have the opportunity to increase
sales by 20 percent and gross margins by 40 percent by providing solutions which
give the customer the lowest total cost of ownership (LTCO). This is the latest
prediction in N064 Air/Gas/Water/Fluid Treatment and Control: World Market.
Function |
Component Examples |
2017 World Revenues |
Flow Control Liquids |
Pumps, Valves |
160 |
Flow Control Air/Gases |
Compressors, Fans, Dampers |
45 |
Filtration and Separation of
Liquids |
Filters, Centrifuges,
Clarifiers, Cross-flow Membranes |
50 |
Oxidation and Destruction
Treatment for Liquids |
Biological and Chemical
Treatment including
Digesters, Aerators, Treatment
Chemicals, etc. |
60 |
Indoor Air and Stack Gas
Treatment |
Filters, Scrubbers, Catalytic
Reactors, Nozzles |
80 |
Total |
|
395 |
Component sales in 2017 will be just under $400 billion. However, if component
suppliers were to pursue the solutions approach, the potential expands to well
over $500 billion. This is easier said than done. The component supplier needs
to understand the customer needs. In turn, this means understanding the sub
process, the process and the industry.
The Role of Components in
Solutions |
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Industry |
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Process |
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Sub Process |
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Solutions |
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The LTCO Valve
Product |
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If the supplier thoroughly understands the customer needs, he can tailor his
product to best fit those needs.
Let’s take an example. A typical valve controlling compressed air is a commodity
product. One application involves pulsing air to clean filter bags. Pentair has
become the world leader in this specialty niche by understanding the dust
collection cleaning process and the variations needed for various different
industries. Pentair supplies not only the valves but the headers and the
controls to optimize the cleaning process.
Many industries need evaporation processes. Mechanical Vapor Recompression (MVR)
is one sub process which minimizes total energy consumption. Colfax Howden has a
number of blowers and fans to offer depending on the flow and temperature
increase needed. However, it has also developed the ExVel® fan
specifically for this unique application. The impellers are suited to abrasive
and corrosive conditions encountered as the steam is recompressed.
W.L. Gore has developed a number of innovative solutions based on process and
industry knowledge. Most power plants have wet flue gas desulfurization (FGD)
systems. There are new rules to reduce mercury. Wet FGD systems will remove most
of this mercury with the right treatment chemicals. The conventional solution to
remove the remainder of the mercury is to use activated carbon upstream. The
problem is that any mercury removed by the carbon reduces the amount captured in
the scrubber. W.L. Gore developed a module which can be installed after the
scrubber and efficiently remove remaining mercury.
Flowserve is a major supplier of pumps for reverse osmosis (RO) processes.
Desalination of seawater is a big potential market. High energy cost is one of
the major factors reducing the market potential. Flowserve understood that a
solution was energy recovery and acquired a company to provide it. (Calder DWEER™)
Most flow control and treatment equipment will be purchased in countries with
less application experience than in the past. This means that international
suppliers have a great opportunity to develop and sell solutions to ensure that
the customer selects the lowest total cost of ownership (LTCO).
For more information, click on:
N064
Air/Gas/Water/Fluid Treatment and Control: World Market
Total Solutions is the Best Path for International Air Pollution Control
Equipment Suppliers
The number of regulated air pollutants, stringency of regulations and technology
are all changing rapidly. No one would have predicted that direct sorbent
injection would be a success twenty years ago. In the preceding decade, lots of
research money had been spent in the U.S. on the assumption that 60 percent SO2
removal would be sufficient. When the regulators ultimately opted for 90 percent
efficiency, dry sorbent injection (DSI) was taken off the table. Now, with new
hydrated lime technology and the willingness of power plants to spend lots of
money for sorbent to avoid capital investments, the outlook for DSI is very
promising.
Today, plant owners must consider technologies that remove particulate, acid
gases, mercury, CO, CO2, NOX and organics. Some
technologies create new air and water pollutants which must also be addressed.
Various industries have unique challenges. They also have many identical needs.
Cement plants should pay attention to developments in the coal-fired power
sector and vice versa. McIlvaine just hosted a webinar which concluded that
ionic liquid impregnated pellets designed for natural gas mercury removal could
have wide applicability in power, waste-to-energy and other industries.
McIlvaine publishes a number of specific market reports and databases on each
technology and industry. It also publishes 5AB
Air Pollution Management to guide executives making strategic
decisions for their companies. One of the recommendations is to be a “Solutions
Provider” whether you are selling complete systems or just a component.
Air Pollution Control Solutions |
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Industry |
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Process |
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Sub Process |
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Solutions |
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The LTCO
Air Pollution Control
Product |
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Let’s take an example. A typical valve controlling compressed air is a commodity
product. One application involves pulsing air to clean filter bags. Pentair has
become the world leader in this specialty niche by understanding the dust
collection cleaning process and the variations needed for different industries.
Pentair supplies not only the valves but the headers and the controls to
optimize the cleaning process.
W.L. Gore has developed a number of innovative solutions based on process and
industry knowledge. Most power plants have wet flue gas desulfurization (FGD)
systems. There are new rules to reduce mercury. Wet FGD systems will remove most
of this mercury with the right treatment chemicals. The conventional solution to
remove the remainder of the mercury is to use activated carbon upstream. The
problem is that any mercury removed by carbon reduces the amount captured in the
scrubber. W.L. Gore developed a module that can be installed after the scrubber
and efficiently remove remaining mercury.
This technology fits particularly well into the processes employed at sewage
sludge incinerators and power plants. It is less attractive in some other
industries. The reasons have to do with the sub processes, processes and the
specific industries. The air pollution control solutions provider who
understands all these aspects is in a position to offer the product with the
lowest total cost of ownership (LTCO). This knowledge is the key to success in
the international market. In fact, owners and operators in developing countries
are in greater need of these insights than those in developed countries.
For more information on 5AB Air
Pollution Management, click on:
http://home.mcilvainecompany.com/index.php/markets/2-uncategorised/100-5ab
Daily Project Posting in McIlvaine Oil, Gas, Refining Supplier Program
OIL/GAS/SHALE/REFINING
E-Alert
April 2016 – No. 2
This alert is being issued twice per month for suppliers in flow control and
treatment who are coordinating market research with targeted pursuit of the
larger and longer term orders.
PROJECTS
The following projects each will result in millions of dollars of orders for
flow control and treatment products. Each project has been rated. The
opportunity size is rated from 1-10 with 1 being small and 10 being very large.
The timing for flow and treatment orders has been provided by year, e.g. T 16 =
timing of order is 2016.
Chevron Phillips Chemicals Reaches FID on Cedar Bayou Plant Expansion (T16)
BP, Kuwait Petroleum Sign Framework Agreement
Williams Advances Unique Position in Canada with Startup of Second Offgas
Processing Plant
Rangeland Energy Begins Development of South Texas Energy Products System
(STEPS)
TransCanada to Buy Columbia Pipeline Group for $10.2 Bln
Primus Green Energy’s North American Methanol Plants Allow for Local,
Cost-Advantaged Production
Suncor Energy Completes Acquisition of Canadian Oil Sands
Norwegian Awards in Predefined Areas (APA) 2016 Announced
New Zealand Offers Five Petroleum Permits in 2016 Tender
Veresen Concludes Key Terms with JERA for Jordan Cove Liquefaction Capacity
(T17)
Methanol Plant Engineering Services Contract Awarded to Toyo Engineering (T16)
Amec Foster Wheeler Awarded Feasibility Study Contract for Karachi Refinery
Upgrade (T16)
These projects are covered in more detail and are integrated in a database which
is part of Oil, Gas, Shale and Refining Markets and Projects. This semi-monthly
report is available as part of this service or as a stand-alone subscription.
The Oil/Gas/Shale/Refining E Alert is issued twice per month to
registered subscribers. It is not to be resent to others. Each subscriber must
be registered. The first subscription is $950/yr. and additional subscribers are
$90/yr. The newsletter is free for those who subscribe to
N049 Oil,
Gas, Shale and Refining Markets and Projects.
There is a 30 percent discount for those building an Opportunity Creation
package with one or more of the market reports and one or more of the E-Alerts.
-------
You can register for our free McIlvaine Newsletters at:
http://www.mcilvainecompany.com/brochures/Free_Newsletter_Registration_Form.htm.
Bob McIlvaine
President
847-784-0012 ext 112
rmcilvaine@mcilvainecompany.com
www.mcilvainecompany.com