Utility E Alert Tracks Billions of Dollars of New Coal Plants on a Weekly Basis
Many of the new coal plants in planning or early construction are in Asia. Here are headlines from the Utility E-Alert last week:

• Sri Lanka plans Coal-fired Power Plants in South
• Three International Companies submit Tender for Rampal Coal-fired Power Project
• Carbon Offsets Plan could clear the way for Coal-fired Power Plants in British Columbia
• Valmet to supply FGD and Denitrification Installation for CIECH Soda Polska SA
• MET awarded Contract for ESP upgrade for a Coal-fired Utility Boiler in Caribbean
• Environmental Clearance granted for imported Coal for 1,980 MW Coal-fired Ghatampur Power Station in Uttar Pradesh, India
• Proposed Shivee-Ovoo Coal-fired Power Plant at Shivee Ovoo Coal Mine in Mongolia
• China Datang planning Two-Unit Ultra-Supercritical Coal-fired Power Plant in Anhui Province
• TBKi supplies Limestone for Indonesian FGD
• Shenhua Group planning 2,000 MW Ultra-Supercritical Coal-fired Power Station for Hefei, China
• Two additional Subcritical Coal-fired Units planned for Huaibei Guo'an Power Station
• Daihai-3 1,200 MW Coal-fired Power Plant in Inner Mongolia Autonomous Region
• Phase V of Expansion of Coal-fired Tuoketuo Power Station planned by Datang
• China Datang proposing 2,000 MW Coal-fired Power Plant for Datang Zhunge’er Al-Si-Ti
• Emerson wins Order from NTPC for Automation Technologies for Two 800 MW Supercritical Units
• Indonesia is behind other Asian Countries relative to NOx and SOx reduction
• China adding 20,000 MW/yr for next 10 Years
• Japan to build 40 New Coal-fired Power Plants
We are also tracking air pollution projects such as FGD projects by Doosan in Vietnam and new regulations in the U.S.

 Effluent Guidelines to be released Next Week
 Hamon Bookings down in First Half
 TECO Energy closes the sale of its TECO Coal Subsidiary
 Doosan is a Major APC Supplier in Asia
For more information on this weekly Utility E Alert click on: 41F Utility E-Alert
Forecasting of Products for Individual States and Individual End Users within the U.S.
The standard McIlvaine market reports divide the world in 80 regions. The U.S. market is approximately one quarter of the total. The top 10 countries account for half the total. The remaining 70 countries and sub regions each average just 0.7 percent of the total. If one divides the U.S. into nine regions, the average region is 2.8 percent or four times as large as the average of the 70 countries. Some States such as California have as much as 10 percent of the National market which converts to 2.5 percent of the world market. So a State such as California ranks among the top 20 if compared to other countries. It, therefore, makes sense to forecast the individual State markets for important products. Purchasers of the McIlvaine multi-client market reports can receive this additional revenue forecast on an electronic spreadsheet. The level of detail is shown below:

Alabama - Specific Product XX Revenues 2019 ($ Millions)

Industry Segment XX Product Sales
($ Millions)
% of U.S
Basis for Forecast
Criterion for Large User
# of Large Purchasers
Food xxx xx production More than 500 employees xxxx
Wastewater xxx xx mgd 15 mgd xxx
Coal Fired Power xxx xx MW 500 MW xx
Nuclear Power xxx xx MW 1000 MW x
Refinery xxx xx Bbl/day All 130
Pharmaceutical xxx xx production More than 500 employees xxxx
All industries included in basic market report will be included
Total For State of Alabama
Total for South East (one of 9 regions for the U.S.)
A relatively small number of companies purchase the majority of any product. McIlvaine is identifying these companies individually. The State forecast provides the useful total of large users in each industry segment. This forecast can be supplemented with details on each large user.
For some products it may make sense to forecast revenues for sub categories, e.g. splitting iron and coal from general mining or split among the various food categories such as:

3111 Animal Food Manufacturing
3112 Grain and Oilseed Milling
3113 Sugar and Confectionery Product Manufacturing
3114 Fruit and Vegetable Preserving and Specialty Food Manufacturing
3115 Dairy Product Manufacturing
3116 Animal Slaughtering and Processing
3117 Seafood Product Preparation and Packaging
3118 Bakeries and Tortilla Manufacturing
3119 Other Food Manufacturing
3121 Beverage Manufacturing
For more information on State Revenue Forecasts contact Bob McIlvaine at rmcilvaine@mcilvainecompany.com 847-784-0012 ext. 112.
Why international suppliers should focus on the top 200 prospects (Arcelor Mittal example)
Many companies recognize the importance of large customers and have assigned personnel and resources to them. By providing precise forecasting and organized information on large customers, this major opportunity can be maximized. McIlvaine achieves this with the Detailed Forecasting, Large Project Tracking Program. The important parameters are:

• The top 200 suppliers buy more than 60 percent of the products and services.
• A special program should be created to sell to this group.
• International suppliers have the best opportunity selling to large international customers.
• International customers want global suppliers.
• Large customer are willing to pay higher prices for higher quality equipment and services and are willing to expend the effort to make a total cost of ownership evaluation.
• Precise forecasting by product, company and project coupled with timely information will provide the supplier with the tools he needs.
The Arcelor Mittal example:
Arcelor Mittal is one of the top 200 flow control and treatment purchasers. Arcelor Mittal produces 98 million tons of steel per year at 194 sites. It produces twice as much as the nearest competitor or 6 percent of the 1.6 billion tons of steel produced last year. It is also one the largest mining companies with both iron ore and coal mining capacity. The company has production sites around the globe making it one of the top 200 purchasers of flow control and treatment equipment. Last year it purchased 1.3 percent of the fabric filters and bags. It is a major valve purchaser with some plants operating more than 50,000 valves.
The company has adopted a global procurement program based on total cost of ownership. This program launched in 2007 places emphasis on life cycle cost and not initial price. It seeks long term relationships pooling knowledge and deploying specialized technical knowledge. This means that companies with better products have the opportunity to charge the prices commensurate with product value. They also have an opportunity to provide global service to help ensure the lowest cost of ownership.
Air Programs: The company is focused on reduction of dust, NOx and SO2. The capital investment in steel plant air pollution control projects in 2014 was $180 million. Dust emissions were 621 grams per ton of steel produced which is down 24% percent of the 2010 level. NOx emissions fell 4 percent in 2014 to 1.1 kg/ton of steel and SOx emissions decreased 3 percent.
Dust emissions from mining operations fell 6 percent to 5.3 million tons in 2014 while NOx fell 3 percent and SOx 26 percent (mainly due to a fuel change).
In 2014 ArcelorMittal R&D division worked on 13 air emission projects to improve dedusting systems and also processes.
Water Programs: The steel plants use large quantities of water for cooling and are located adjacent to lakes or rivers. Of 134 steel sites, 20 are located in regions which are experiencing water stress or scarcity. As a result, the Global R&D group is focused on water reuse and zero liquid discharge. The water treatment laboratory in Asturias, Spain is investigating green technologies to minimize pollutants.
Water at the mines needs to be treated before discharge. Water is also used for dust suppression, transporting tailings and concentrating ores. Some mines such as El Volcan in Mexico use special thickeners to avoid the use of tailing ponds.
The Indiana Harbor Works has installed a zero liquid discharge system (ZLD). The Newcastle, S.A. site has just commissioned a $40 million facility to treat wastewater. ZLD is already being accomplished at Saldanha and Vanderbijlpark. Two mine water treatment plants are in design and construction in Kazakhstan. A major water reduction program has been underway in Romania.
Arcelor Mittal in McIlvaine Program
Several McIlvaine project tracking systems cover the large ArcelorMittal projects around the world.

Location Timing Project Description
Aviles/Gijon
Spain 2016-2019 Reconstruction of two of 45 coke oven batteries with collection and scrubbing system.
Ghent, Belgium 2016-2017 $100 million bio ethanol plant using CO gas from steel with eventual capacity of 47,000 tons of ethanol/yr.
Germany 2016 Minor projects in Bremen, Duisburg, Brandenburg and Hamburg including galvanizing lines and new pre heat furnace.
Bosnia -Herzegovina 2015-
2016 New dust filters for BOF furnace with mid 2016 completion date. New filters for sinter plant are already installed. Sinter machine #4 precip internals also replaced.
Calvert Alabama 2015-
2016
$6.7 million for coating line with pumps and $40 million for slab yard expansion.
Ostrava
Czech Republic 2014-2016 Valmet is supplying new CFB coal-fired boiler to replace old existing coal-fired boilers. Fabric filters will be used for dust capture.
Ostrava
Czech Republic 2014-2016 ZVVZ-Enven Engineering is supplying $25 million DeSOx project and CKD Phraha is supplying a $50 million DeNOx system.
Hunan Valin
China 2014-2017 New $832 million automotive steel plant.
Acindor
Argentina 2013-
2017 400,000 ton/yr. rolling mill was initiated in 2013 with expectation of a two year completion date. Five other production lines at the site produce 1.7 million tons/yr.
Dunkirk
France 2013-2015 New $110 million revamp of blast furnace #2 to be completed this year.
There is also detail on specific plants:
ArcelorMittal Burns Harbor LLC
Unit ID: Hot Dip Coating Line Annealing Furnace Click on Unit ID to view Emissions Data
Equipment: Selective Catalytic Reduction - SCR
Installation Year: 1999
Primary Contact Name: Robert Maciel Manager, Environmental Services
Telephone: 219-787-4973 E-mail: robert.maciel@arcelormittal.com
ArcelorMittal Cleveland Inc.
Unit ID: Boiler 3 Click on Unit ID to view Emissions Data
Operating Hrs. /Yr.: 8760 Fuel: natural gas, coal
Equipment: Electrostatic Precipitator
ArcelorMittal Indiana Harbor LLC
ArcelorMittal Lackawanna LLC
There are links to air and water permits with considerable detail on each emitting source:

• Arcelor Monessen coke plant Air permit from 2014-2019 covering coke oven pushing and quenching the desulfurization plant, the coke pushing baghouse and benzene NESHAPS control system but an environmental group PennEnvironment is suing the plant for emitting excess soot, acidic gases and noxious odors since the decades-old facility went back into operation in April 2004.
• Minorca Mine Virginia City Minnesota air permit with requirements for fabric filters and scrubbers used in the concentrating and pelletizing of 9 million tons/yr. of taconite ore to manufacture 3 million tons/yr. of pellets.
• Weirton West Virginia 3 small oil- and gas-fired boilers air permit expires in 2016. A 2012 Title V permit expiring in 2017 covers the reheat furnaces, hot strip mill pickling lines and HCl regeneration. An NPDES permit on the water side covers 18 mgd of cooling water discharge and 9 mgd of treated wastewater.
• Dofasco Ontario facility paid $390,000 penalty in 2014 for excess blast furnace emissions.
• ArcelorMittal Steel USA, Inc. - IN Harbor East, Permit No. IN0000094 - RENEWAL covers iron & steel, rolling mill operations and finishing operations with additional support operations: power generation, wastewater treatment with discharge to the turning base and ship canal. Several storm water outfalls which have the potential to discharge to these waters are also covered by this permit.
There are details on specific flow control and treatment products:
Pumps: Hydro descaling pumps are used at the Indiana plant. Weir received an order for $2.8 million for Warman slurry pumps for tailings transfer at Krivoy, Ukraine.
Sedimentation/Centrifugation: Dawco installed a 43m diameter thickener, a 25m diameter water tank, a pump house building and a piperack that connects to the concentrator sector of the Mount Wright Iron Mining Complex in Fermont, Québec.
Monitoring: CiDRA SONARtrac® Process Monitoring Technology is used for product transfer measurement on a 27 km hydrotransport slurry pipeline in Mexico that runs from nearby mines to steel plant in Lázaro Cárdenas City, Michoacán. A high pressure pump injects the slurry into the steel pipeline for the 27 km transit to the pelletizer plant.
Valves: ArcelorMittal Tubarão (formerly CST-Arcelor) Brazil, had Life Cycle contracts with Metso for all automated control, manual and safety valves throughout the ArcelorMittal Tubarão’s plant in Serra City. The total is almost 40,000 valves and included over 700 control valves.
In 2015, ArcelorMittal Tubarão, awarded SGS a four-year contract for the maintenance of security and control valves. A specialist team of 30 experts will detect the type of maintenance required for each valve. Valves will then be removed, opened, serviced and reinstalled. If major repairs are required, the valve will be taken to the dedicated SGS workshop in the city of Serra.
ArcelorMittal Gent is using 25 Econ-ARI Stevi® control valves and accessories from Econosto in order to reduce power consumption in a series of heat exchangers. With this investment, the steel producer expects to reduce its energy bill by between € 60,000 and € 80,000 per year.

For more information on Detailed Forecasting, Large Project Tracking Program. Contact Bob McIlvaine at: rmcilvaine@mcilvainecompany.com 847-784-0012 ext. 112.
Over 70,000 MW of Solid Fuel Fired Generators Slated for 2017

Suppliers are pursuing projects totaling $100 billion for new coal-fired and biomass boilers slated to start up in 2017. These projects are continually tracked in World Power Generation Projects. The combustors, steam turbines and some of the other long delivery items have already been ordered but decisions on dampers, pumps, valves, nozzles, filters and controls are now being made.
Five of the projects are in Africa, nine are in Europe, two are in South America but the remainder are in Asia. China has the largest number. Five of the projects will use biomass as the primary fuel. Four of these are in Europe and one in India. The 30 non-Chinese Asian projects are shown below:

Fuel Project Name Total Size (MW)
Biomass Vemagiri expansion-GMR, India 768
Coal ACB India Chhattisgarh power plant Kasaipalli, India 900
Coal Barethi power plant-National Thermal Power Corp., India 3960
Coal Chhabra 5,6 power plant-Rajasthan Rajya Vidyut Prasaran Nigam, India 1320
Coal Chipoka power plant-Intra Energy Corp., Malawi 120
Coal Enugu-Minaj Holdings Ltd. power project, Nigeria 1000
Coal Exxaro/GDF Suez power plant, South Africa 600
Coal Gadarwara supercritical power plant -NTPC, India 1600
Coal Genting Ltd power Project in Banten province, Indonesia 660
Coal Godda power project-Jindal Steel and Power, India 1320
Coal Jambi province power plant-EGAT/ Intermining and Energy, Thailand 500
Coal Long Phu 1 supercritical power plant-PetroVietnam, Vietnam 1200
Coal Maitum (Kamanga) (Alcantara) CFB power plant-Sarangani Energy, Philippines 210
Coal Mangrol power plant-Gujarat Industries Power Co., India 600
Coal Manjung 4 supercritical expansion-Tenaga Nasional Bhd., Malaysia 1000
Coal Manuguru power plant-Telangana State Power Generation, India 1080
Coal Meja supercritical power plant-NTPC, India 1320
Coal Mong Duong 2-AES, Vietnam 1200
Coal Mota Layja village power plant-Infrastructure Leasing & Financial Services, India 4000
Coal Nabinagar supercritical power plant-NTPC/Bihar State Electricity Board, India 1980
Coal No. 304 Industrial Estate power plant-National Power Supply power project, Thailand 540
Coal Pagbilao 3 CFB expansion-Aboitiz Power and TeaM Energy Philippines, Philippines 400
Coal Pemalang supercritical power plant-PLN, Indonesia 2000
Coal Qadirabad (Sahiwal district) power plant, Pakistan 1320
Coal Sampur-Ceylon Electricity Board/National Thermal Power Corp., Sri Lanka 500
Coal Sinboryeong ultrasupercritical power plant 1,2 -Korea Midland Power, South Korea 2000
Coal Solapur supercritical power plant-NTPC, India 1320
Coal Subic Bay power plant-Kepco Philippines Corp., Philippines 300
Coal Sundergarh supercritical power plant-Coal India/Mahanadi Coalfields, India 1600
Coal Talin 2 supercritical rebuild-TaiPower, Taiwan 800
Coal Termonorte power project-Produccionj de Energia, Colombia 88
Coal Tuzla 7-Elektroprivreda BiH (EPBiH), Bosnia 450
Coal Van Phong 1 economic zone power plant-Sumitomo/Bach Dang-Hanoi Co., Vietnam 1320
Coal Vodarevu UMPP, India 4000
For more information on 40A World Power Generation Projects, click on:
http://home.mcilvainecompany.com/index.php/databases/28-energy/486-40ai
200 Companies Account For 75 Percent of All Fabric Dust Collector and Bag Purchases
Two hundred end users and OEMs will purchase 75 percent of all the fabric filters and replacement bags in the next ten years. This is the conclusion reached by the McIlvaine Company in N021 World Fabric Filter and Element Market.
One hundred twenty-six companies will account for over 60 percent of the fabric filter system purchases in 2015 and over 50 percent of the purchases over the next ten years. The discrepancy between the concentration in one year and the concentration over time is that certain companies, e.g. Eskom will buy a disproportionate quantity of filters in one year. The following analysis includes 50 cement companies, 50 power companies, 10 mining companies, 10 chemical companies and 6 steel companies. When another 24 steel and chemical companies are added, the total is 150 companies which will purchase over 60 percent of the systems and bags over the next ten years. An additional 50 companies will purchase another 15 percent bringing the total to 200 companies accounting for 75 percent of the total.
The following chart shows purchases by individual companies and groups. The list is ranked by 2015 contribution to purchases. The largest individual purchaser is Eskom with 10 percent of the system purchases. Some small long range purchasers rank high on the 2015 list due to large one time projects. Colorado Springs Utility and Essar Steel are examples (not shown in the extract below). The importance of the onetime purchasers is much less in the bag segment than in total systems.
Fabric Filter Purchases by Company


Company % of 2015 Fabric Filter Market
Potential
($ billion)
Market
% of Potential Market %
Present Penetration
% High
Temp
50 Power Companies with 2015 Purchases 20 10.0 Coal-Fired 5.4% 10 90
Eskom 10 3.0 Coal Fired 1.6% 40 90
Cement Companies, Ranked 7-50 5 6.0 Cement 3.2% 80 60
Top 10 Mining Companies in 2015 4 5.0 Mining 2.7% 80 60
Top 10 Chemical CompaniesiIn 2015 4 5.0 Chemical 2.7% 80 40
Steel Companies, Ranked 2-6 3.3 5.0 Steel 2.7% 80 60
Top 10 WTE in 2015 3 2.0 WTE 1.1% 80 95
Arcelor Mittal 1.3 2.0 Steel,
Coal-Fired
Iron Ore 1.1% 80 50
Lafarge 1.2 1.5 Cement 0.8% 80 60
Holcim 1.2 1.5 Cement 0.8% 80 60
Relatively few power companies are among the top purchasers in 2015 but many are among the top potential purchasers. McIlvaine is tracking large conversions of precipitators to fabric filters. If all the coal-fired power plants converted to fabric filtration, the investment would be $80 billion just for the hardware and over $200 billion for the installed systems. The systems would clean 8 billion cfm of flue gas and would require 4 billion square feet of filter bags. The challenge is to determine how fast and how much capacity will switch. The market will be driven by the regulations in each country. McIlvaine is assessing the effect and timing of these regulations and is adjusting its forecasts continually.
For more information on N021 World Fabric Filter and Element Market, click on: http://home.mcilvainecompany.com/index.php/markets/2-uncategorised/110-n021


Bob McIlvaine
President
847-784-0012 ext. 112
rmcilvaine@mcilvainecompany.com
www.mcilvainecompany.com