$18.7 Billion Market for Sedimentation and Centrifugation Solutions by 2026
The market for sedimentation and centrifugation equipment will expand from $7.5
billion in 2016 to $9.8 billion in 2026. On-site service will expand
from $1.45 billion to $1.94 billion in the same period. The biggest growth
potential is in remote service and monitoring which will increase from $200
million/yr. to $3 billion. If the potential for related remote monitoring
is included, remote monitoring and service will generate revenues of $7 billion
by 2026. These are the new predictions in
N005 Sedimentation and Centrifugation World Markets.
Sedimentation and Centrifugation
Revenues $ Millions |
|||
Segment |
2016 |
2021 |
2026 |
Centrifuge Equipment |
3,000 |
3,500 |
4,000 |
Service On-Site |
750 |
875 |
1,000 |
Remote Service and Monitoring |
100 |
700 |
1,800 |
Sedimentation Equipment |
4,500 |
5,100 |
5,800 |
Service On-Site |
700 |
810 |
940 |
Remote Service and Monitoring |
100 |
600 |
1,200 |
Related Remote Monitoring and
Service |
50 |
1,000 |
4,000 |
Suppliers of sedimentation and centrifugation equipment have the opportunity to
take advantage of the rapid growth in automation and remote monitoring and
service. Companies such as Alfa Laval and Evoqua can take a leading or
secondary role. Alternatively, the lion’s share of the revenue can be garnered
by third party O&M operators such as Veolia and Suez. Software developers
such as Emerson, ABB, Siemens and GE could also take a leading role. However, GE
is exiting the water treatment chemicals and equipment business, so this does
not seem to be in their game plan.
Centrifuge manufacturers are well positioned to take a leading role due to the
challenging maintenance requirements for this high-speed equipment. Many
centrifuge manufacturers already have remote monitoring programs.
Centrysis wireless remote monitoring is web based and tracks 32 key parameters.
It includes alerts, reports and service.
Alfa Laval has a number of remote monitoring initiatives including decanter
centrifuge condition monitoring at the Metropolitan Wastewater Reclamation
District of Chicago. Vibration is monitored and controlled through a X20 PLC
from B&R industrial Automation. A custom I/O module has reduced costs and
made remote monitoring attractive.
Alfa Laval has expanded the concept to related remote monitoring and service.
The Octopus biosolids dewatering centrifuge autopilot monitors and controls all
aspects of the dewatering process. This includes material feed, polymer
dosing and internal decanter settings. Infrared sensors analyze performance and
automatically make necessary adjustments. Alfa Laval also manufactures
pumps, valves, heat exchangers and belt filters used ahead of centrifuges.
This knowledge can be leveraged to provide O&M for the complete process.
GEA Westfalia is well positioned to take advantage of this opportunity.
Their various businesses have been combined into just two. One is equipment and
the other is solutions. Engineering has also been centralized.
Several years ago, GEA would have bid only portions of a starch plant and now it
can bid for the entire plant. Taking the next step to offering remote O&M
for that plant is now an option.
Sedimentation and centrifugation suppliers should also position themselves to
take advantage of the opportunity to provide remote monitoring and service in
collaboration with other suppliers or as sub-contractors to an integrator.
GEA has the opportunity to be one of the participants in remote O&M of gas
turbine plants. Plant suppliers such as MHPS have set up remote control centers
to monitor turbines. They are now expanding into the balance of the plant.
This includes treatment of the oil which is often a secondary fuel for gas
turbines.
GEA supplies centrifuges to purify the oil. The gas turbine manufacturers
specify limits for the trace elements to ensure safe and economical operation.
For sodium and potassium these limits are between 1 ppm and 0.1 ppm. The harmful
water-soluble trace elements are reduced to the required levels by separation
only or by a combination of washing and separation. Contaminants such as sand,
rust and cat fines are removed from the fuel oil under high centrifugal force.
The measurement of some fuel parameters can be continuous. PECO Facet uses
light scattering techniques to monitor particles in the gases. However,
measurement of the contaminants in the fuel oil requires periodic laboratory
analyses.
The integrated system would incorporate the centrifuge condition monitoring with
both laboratory and online fuel sampling. If the end user, system supplier, oil
quality monitoring supplier and centrifuge supplier all have access to the
online data then better decisions can be made.
For more information click on
N005
Sedimentation and Centrifugation World Markets
$125 Billion/yr. Power Plant IoT Instrumentation, Software and Service
Opportunity
World electricity consumption is 25,000 terawatt hours per year. Generation of
this electricity costs $2.5 trillion per year. Machine to machine
communication in combination with remote monitoring and service has the
potential to reduce this cost by 5 percent and create a $125 billion dollar per
year opportunity. This is the latest forecast in a special ongoing
analysis included in
N031 Air
and Water Monitoring: World Market.
The opportunity incorporates, smart instrumentation, component monitoring,
digital data generation at the plant, software programs, remote monitoring,
third party operation and maintenance and a combination of subject matter
experts and data analytics.
Smart Instrumentation
The opportunity is shaped by the ability of sensors to accurately detect the
flow of liquids, gases, air, water and solids. The quality of the flow is
also critical. Continuous emissions monitoring systems measure the air
contaminants such as NOx, SO2 and particulate. New
regulations have added the need to measure mercury in the exhaust gas and
selenium in the wastewater. The temperature, moisture and particulate levels for
lubricating fluids used in the rotating equipment are also important.
The need for accurate injection extends to corrosion and scale inhibitors,
biocides, pH adjusters, polymers for wastewater treatment and many new chemicals
needed for air and water pollution control. These include activated
carbon, lime, limestone, ammonia and urea.
Ambient air and water measurement needs include wind measurement for wind
turbine optimization, ambient air and water measurement in areas surrounding the
plant and many predictive weather measurements for solar and wind operations.
All of these measurements are being enhanced by the development of smart
sensors. Tunable diode lasers allow measurement of O2 at
critical points in the combustion zone. The incorporation of an analysis
function within the instrument itself rather than through the distributed
control system has cost advantages and more importantly shortens response time.
Suppliers of this instrumentation are found in the McIlvaine Air and Water
Monitoring report in many categories and sub categories.
Measurement Categories |
Examples |
Function |
Analysis, extraction,
integration, display, services,
consumables, accessories |
Medium |
Ambient air and water, process
liquids and gases, solids, oil,
injection chemicals |
Properties Measured |
Physical, chemical, electrical,
other |
Measurement Parameters |
Count, weight, volume,
temperature, pressure,
contaminants, viscosity |
Operating Principles |
Chemical, electrochemical,
light, opacity |
Mode of Use |
Continuous, hand held,
laboratory, process |
The opportunity varies widely depending on the fuel source. Coal
represents the largest potential because it is the leading type of generation
and has high needs for measurement.
Instrumentation Market Size by
Medium Measured |
||||||
Fuel Source |
Weather |
Water |
Air |
Process Liquids |
Process Gases |
Solids |
Coal |
S |
H |
H |
M |
M |
H |
Nuclear |
S |
H |
M |
H |
H |
M |
Gas |
S |
M |
H |
S |
S |
S |
Solar |
L |
S |
S |
S |
S |
S |
Wind |
L |
S |
L |
S |
S |
S |
Biomass |
S |
S |
L |
S |
S |
L |
Geothermal |
S |
M |
L |
H |
H |
S |
Hydro |
S |
H |
S |
S |
S |
S |
L= large, M= medium, S= small
Component Monitoring
Condition monitoring of components is well established for lubrication systems
for turbines, compressors, etc. The growth opportunities are in measuring
not only the health but also the operational information of valves, pumps,
filters, separators and other components. Mann + Hummel recognizes this
opportunity and has just invested in a large filtration IoT research center in
Singapore. Pentair, Flowserve and other pump and valve suppliers are
rapidly strengthening their component monitoring capabilities.
Digital Data Generation at the Plant
GE says that coal-fired power plants could be made approximately 4 percent more
efficient with 2.5 percent improvement in efficiencies coming from turbine and
boiler upgrades, and 1.5 percent coming from software improvements. The analysis
also found that applying all potential upgrades to coal-fired power plants can
remove 900 million metric tons of CO2 (11 percent of total coal power
emissions) - more than the annual CO2 output of the United Kingdom
and France combined.
McIlvaine has conducted nine hours of webinars for PacifiCorp with presentations
by GE, Emerson, Siemens and others which pointed the way to large savings with
combustion optimization. The reduction in NOx emissions was
particularly significant.
Software Programs
The software programs include partnerships between power plant system suppliers
and specialized software providers. GE says Predix will enable GE to lead
the next generation of industrial progress, through improved manufacturing
processes and digitally manufactured products, transforming GE into a stronger
and more valuable company. GE believes its digital business will grow GE’s
software and analytics enterprise from $6 billion in 2015 to a top 10 software
company by 2020. GE has purchased NEUCO who has developed neural networks to
control not only the operation of the furnace but also components such as soot
blowers.
General software participants include large companies such as Intel with its
Wind River subsidiary and specialist companies such as OSIsoft and SoftDEL.
Remote Monitoring
The large gas turbine suppliers have remote monitoring centers which primarily
track the health of rotating parts. This is frequently part of the
warrantee program. However, companies such as MHPS are branching out to
monitor more of the plant’s components. MHPS just opened a remote
monitoring center in the Philippines which is monitoring coal-fired power
plants. The service center can also provide assistance to power plants not built
by MHPS. In addition to its data analysis capabilities, the center can also
manage maintenance equipment and dispatch staff in emergency situations. It
will, in addition, serve as a training hub for technicians. Every year, around
200 individuals will be picked from both in and outside the company to transfer
technical expertise on maintenance and management.
There is a huge potential for companies such as MHPS and GE to work with other
suppliers and incorporate hundreds of individual remote monitoring programs.
For example, Nalco operates an around the clock monitoring center on water
quality. If companies such as Mann + Hummel can operate filter monitoring
centers and, if all the results are integrated for analysis and action, it will
greatly improve the support for the operators.
There is a big potential for interconnection of facilities in large utility
organizations. McIlvaine has been involved with a program for Berkshire
Hathaway Energy.
http://home.mcilvainecompany.com/index.php/decisions/28-energy/1185-4s01
Duke Power has developed central systems which can for example monitor all the
pumps at its various stations.
However, it is shifting away from the traditional centralized proprietary
systems and evolving to support distributed intelligence, interoperability and
IoT. Efforts to develop its smart grid have resulted in the enablement of
these concepts through what the industry calls OpenFMB (Open Field Message Bus).
Third Party Support for Power Plant Operations and Maintenance
Third party operation and maintenance represents the biggest revenue opportunity
for IoT in the power industry.
GE Energy is one of the world’s largest third party providers of plant Operation
and Maintenance services, currently with more than 16,000 MW at 60 sites in 17
countries under O&M contract. Global resources combined with over 20 years of
O&M experience, enable GE to provide complete plant services across the turbine
island and balance of plant—for both GE and non-GE equipment.
Siemens, MHPS, IHI and other turbine suppliers also offer similar services.
There are a number of companies specializing in O&M including large companies
such as Wood and smaller companies such as Ethos Energy and Proenergy.
Uniper and India Power have formed a joint venture to support operations and
maintenance at Indian power plants.
Data Analytics and Subject Matter Experts
The generation of large amounts of data is not of value unless it is properly
analyzed for action. XLMPR recommends hybrid data analytics marrying the
experience based models with ones based on physics and data. The IoT
greatly increases the capability for database models but this data needs to be
molded by experience. Subject matter experts are needed to provide the
niche expertise in each of thousands of areas. The pool of recently
retired people can be tapped for their unique combination of knowledge and
availability for short engagements.
The analysis and forecast of IoT instrumentation, software and service
opportunities in Power Generation is included as a special report in
N031 Air
and Water Monitoring: World Market
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
#1303 – December 30, 2016
Table of Contents
COAL – US
• Regional Haze Ruling boosts
Texas Scrubber Market
• NRG Energy, Inc. converts four
of its Power Plants from Coal to Natural Gas
• FPL to retire 250 MW
Coal-fired Cedar Bay Power Plant in Jacksonville, FL December 31
COAL – WORLD
• Korea to close 10 aged
Coal-fired Power Plants by 2025
• City in China's Shandong
Province orders Coal-fired Power Plants to cut output due to Smog Notice
•
Australia lobbies China-led AIIB to add Coal to lending priorities
• Two Power Plants of 1320 MW to
be installed at Gaddani
• Nalco Partners with NTPC Ltd
on New 1 MTPA Aluminum Smelter in Odisha
• Doosan Heavy wins $2.3 Billion
Contract to build Coal-fired Power Plants in India
• India’s NTPC commissions First
Unit at 4 GW Kudgi Supercritical Thermal Power Plant
• Duyên Hải-2 has started
Construction
• Duyên Hải-3 (2 x 622.5 MW) and
Duyên Hải-3 Extension (660 MW) to be completed in 2019
• Energa and Enea invite bids to
develop Ostroleka C Power Project in Poland
• South Africa’s Kusile Power
Station’s Unit 1 connected to the National Grid
•
Thai Binh 2 Thermal Power Plant 65 Percent Complete
• Ducon receives another FGD
Contract in India
• Mitsubishi Hitachi signs
Supply Contract for FGD System at Ugljevik Thermal Power Plant in West Balkans
• Mahagenco Koradi will install
FGD
• India Environmentalist
forecasts 300 Percent increase in Coal-fired Power
•
Unicon is active in ESPs and other APC in India
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.
----------
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