FABRIC
FILTER       NEWSLETTER 

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February 2009
No. 400

 

The Market in General and Filtration Specifically:

Heimbach Filtration

 

 Heimbach has announced the closure of their factory in Suzhou, China. Their announcement noted the enduringly worsened market for filtration products in China and fierce price competition in Asia (particularly within China.)

 

Donaldson

 

Donaldson Australasia has teamed with Eximo on their Unimaster dust control unit designed to handle nuisance dust in industrial applications.

Baird, a UK based financial analyst reduced their forecast for Donaldson (DCI) noting a “series of negative data points and the deterioration in demand”… “aftermarket dealer inventory adjustments and extended holiday plant shutdowns/closures”

 

CNH Global NV

 

CNH Global N.V. (whose principal stockholder is Fiat) reported construction sales declined 38% during 4Q-08. Some forecast the global construction equipment market will be down 30-40% in Q1.

 

Siemens

 

Siemens’s first quarter report (fiscal Q1, 2009) was up-beat. They report increased revenue (up 7%), robust book to bill ratio and better order development than most of their competitors for the first quarter. One project is for dedusting facilities for a new LD (BOF) converter at Novolipetsk Steel  (Russia.)

  

Intensiv- Cementa Sweden

 

Intensiv-Filter obtained a turnkey contract to supply engineering, manufacturing delivery and installation for dedusting equipment to be used at the Cementa rotary kiln located on the Swedish Island of  Gotland. Cementa AB is a subsidiary of HeidelberCement. The Gotland facility  is one of the largest cement plants in North Europe. According to their press release, a ProJet mega for max. 1.223.500 m³/h with pipework, dust discharge system, containerized cargo and fitting will be provided for the installation which is expected to begin in April 2009.

 

Intensiv-Technology

 

Intensiv-Filter announced new in-house CFD (computational fluid dynamics) simulation capability. The software allows Intensiv to optimize operating parameters (fluid simulations and thermotechnical calculations) more efficiently without the extensive engineering costs and test-runs previously required. Prior to obtaining the in-house capability, Intensiv had relied on outside suppliers for this computational capability. 

 

Nuendorfer Training

 

Baghouse Users' Group training will be offered July 28, 29 & 30, 2009 in Willoughby, Ohio.

 

Evonik

 

Evonik;s 1^st Quarter newsletter contains a section on successful P84 blend applications. They note experience showing that PTFE/P84 blends 40 times lower clean gas dust concentrations, lower cleaning cycle time and lower pressure drops than PTFE felt. They recommend this for incinerators, cement and bio-mass combustion applications. The blend using Procon/P84 is recommended for coal fired boilers, cement and police filters on incinerator applications.

 

Farr APC

 

 Farr has produced a new brochure on retrofitting dust collector equipment with their HemiPleat products. The brochure features a reference table to make conversion choices easy for end users.

 

FLSmidth

 

FLSmidth will be hosting “Capital Market Day”  March 16 in London. This program is an informational forum for investors and analysts. Topics will include FLSmidth’s business model and current market conditions. Their goal is to be the “preferred partner and leading supplier to the global cement and minerals industry.” To facilitate that goal they have accelerated their research and development efforts.For instance, they signed an agreement with the “Technical University of Denmark (DTU) and the Danish National Advanced Technology Foundation to make a joint effort towards developing ’the CO2 free plant’. The partners are examining alternative processes for cement production and increased use of alternative fuel which may reduce emissions.

A recent advertisement in Power Engineering touts the A2P fly ash handling system as reducing capital cost by up to 50%.

 

Chemviron Carbon

 

Chemical Cloth International has changed its’ name to Chemviron Carbon Cloth Division.   Chemviron Carbon is the European operation of Calgon Carbon.

 

SMS ELEX AG

 

SMS Demag AG and ELEX have jointly founded a new company (October 2008), SMS ELEX AG whose focus will be to pursue environmental and energy solutions to improve the operating efficiency of their plants. They intend to “produce a new generation of filter systems for cleaning flue gas in steelworks. These filters effectively remove dust from the process gases while keeping costs low and thereby meet the most stringent environmental standards.”

 

United Air Specialists, UAS

 

UAS announced the appointment of Shannon Davis as marketing coordinator.

 

American Fabric Filter Company

American Fabric Filter Company issued a new product release for wood dust collection systems.  Utilizing a felt filter bag paired with a non-breathing plastic collector bag increases filter efficiency allowing filtration down to 1 micron as compared to 30 microns achieves with woven bags.

 

Filter Sense

 

Filter Sense’s advertisement in this month’s Ethanol Producer Trade Publication touted their DeviceNet Baghouse Controller as a  “networking solution that reduces the cost and time required to wire and install industrial automation devices and is a highly effective way to provide access to information in intelligent controls.” The B-PAC instantly detects and locates failed solenoids and filter leaks and lower energy use by employing intelligent pulse cleaning.

 

Lafarge

 

Lafarge has announced modifications at their Exshaw Bighorn facility totaling about $600K.  Joel Taguchi, Community Affairs Manager for Lafarge Canada. noted“This is our chance to focus on maintenance and repair that is difficult to undertake when the market is promoting a strong drive for production.” investigated to subsidize the plant’s current reliance on natural gas and coal, including the possibility of using the sawdust from trees affected by pine beetle infestation. One project is the installation of an Ammonia Injection System. The gravel bed filter system would be replaced by Baghouse technology, in essence a series of filter bags aimed at reducing atmospheric emissions.

 

Tech Cominco, British Columbia

 

Teck is apparently considering the replacement of their Draco Bag house on the  lead smelter furnaces in Trail. The bag house was identified as a significant lead emission source. The cost to replace it is estimated at 25 to 30 million dollars, but Teck is also considering upgrades to the bag house instead.

 

Rand Construction Co.

 

Rand Construction appears to be in line to obtain a contract not to exceed $531,072 for inspection and repair of the Missouri City Power Plant Bag House for the Power & Light Department.

 

 Kiley Paving

 

Community complainst about an asphalt near Odessa, Canada have promted local officials to review permitting for the facility. A new baghouse may be required to alleviate emission problems.

 

News from EUEC, Energy and Environment Conference

 

ADA Environmental Solutions and We Energies (Wisconsin Electric) 

 

presented a paper outlining the findings of an ongoing program at We Energies, Preque Isle to evaluate the affect of powdered activated carbon injection on bag performance. This is part of the demonstration project with the Toxecon™ system which essentially uses DI of carbon and a bagfiltration secondary to the primary particulate collection system.

 

Indigo Technologies presented a paper addressing the quantitative means to determine the impact on fine particulate on opacity and visible emission  issues and describing methods that allow users to identify causes  and determine economical means for solving opacity problems.

 

Mississippi Lime in conjunction with the TVA presented a paper focusing on the use of sorbent injection of hydrated lime when used in conjunction with  a baghouse  for  emission control of SO3 and HCl at a 250MW facility. They note that most large scale sorbent injection systems for SO3 and HCl have been evaluated on ESP systems.

Generally, a review of the subjects of the various papers presented seems to indicate a trend towards focusing on sorbent injection (specifically hydrated lime, trona, carbon and sodium bicarb.) O’Brien and Gere  presented their decision tree using case studies to show that older, smaller  coal fired boilers (where remaining life may be in doubt) can quickly install DI systems at a fraction of the cost of scrubbing.

 

Upcoming Tradeshows etc.

 

World of Asphalt- Tradeshow

Orlando (March 9-12.)

 

Air and Waste Management Association

AWMA 102nd Annual Conference & Exhibition will be in Detroit, MI June 16-19, 2009

 

Technical Trends:

 

EPA- Environmental and Sustainable Technology Evaluations (ESTE)

 

A study was done of two facilities ( one in Minnesota and one in Iowa) to determine the effect of co-firing of biomass in coal-fired boilers on emissions of criteria pollutants and greenhouse gases. The use of biomass has widespread appeal as a means for reducing the use of finite fossil fuel resources. In both facilities the efficiency of the boilers were reduced due to the inclusion of biomass. The affect on particulate and gaseous emissions was varied. http://www.epa.gov/nrmrl/std/etv/pubs/600s08026.pdf

 

EPRI

 

The Electric Power Research Institute (EPRI) announced an intent to perform studies (hosted by five electric utilities in the United States and Canada) on the impacts of retrofitting advanced amine-based post-combustion carbon dioxide (CO2) capture technology to existing coal-fired power plants.

 

Regulations:

 

Medical Incinerators

 

The December 1 issue of the Federal Register noted a proposed rule for emissions from medical incinerators that was more stringent than previous regulations. The new regulation would reduce emissions 500,000 pounds per year as opposed to the previous one that would result in a reduction of only 25,000 pounds per year.

 

Colorado Cement Consent Decree

 

A proposed consent decree was issued in a lawsuit challenging a permit given by the CAA to Cemex for a facility near Lyons in Colorado. The lawsuit was intended to force the EPA to intervene by objecting to the permit process.

 

CEMS Compliance Alternatives

 

40CFR Part 60 has been amended to allow steam generating unit operators to use CEMS (continual emission monitoring systems) to eliminate the opacity standard to demonstrate compliance with PM limit of .030 lb/million.

 

 Aluminum Foundries and Non-Ferrous Foundries

 

40CFR Part 63 has been revised to rename and increase the scope of certain area source categories. For instance “secondary Aluminum Production” is now called “Aluminum Foundries.” At the same time the EPA is establishing national standards for these industries: Aluminum Foundries, Copper Foundries, Other Non-ferrous foundries.

 

Items from the McIlvaine E-Alerts:

 

WorleyParsons gets Contract for Baghouse Engineering at Dan E. Karn

 

Consumers Energy awarded WorleyParsons a $17.5 million contract for the detailed engineering, procurement support and construction management on the installation of two pulse jet fabric filters and associated ductwork, fans and support systems at Dan E. Karn Units 1 and 2.

 

Amendments to EU Pollution Directive Could Halt Construction of

 

Kingsnorth Coal-fired Power Plant

 

Construction of the Kingsnorth coal-fired power station could be threatened by new amendments to a European pollution prevention control initiative. Thursday the environment committee of the European parliament voted on more than 500 amendments tabled to the proposed new legislation – the Integrated Pollution Prevention and Control (IPPC) directive. The proposed IPPC directive incorporates changes to legislation such as the large combustion plant legislation and lays out tighter limits on, for example, SO₂ emissions. 

 

Oregon DEQ BART Proposal for Boardman

 The Oregon Department of Environmental Quality (DEQ) recommends the following Best Available Retrofit Technologies (BART), or equivalent technologies, for Portland General Electric’s (PGE) coal-fired power plant near Boardman, OR.

 

Pollutant	Control Technology	Emission Limit	Averaging Time	Installation Date
Nitrogen Oxides (NOx)	New low NOx burners with modified overfire air system (NLNB/MOFA)	0.28 lb/MMBtu heat input _____________ 0.23 lb/MMBtu heat input	30-day rolling average _____________ 12-month rolling average	7/1/11   __________ 7/1/11
	Selective Non-Catalytic Reduction (SNCR) contingency	0.23 lb/MMBtu heat input	30-day rolling average		7/1/14
Sulfur Dioxide (SO2)	Semi-dry flue gas desulfurization (SDFGD)	0.12 lb/MMBtu heat input	30-day rolling average	7/1/14
Particulate Matter (PM)	Pulse jet fabric filter (PJFF) as part of the SDFGD system and in addition to the existing electrostatic precipitator	0.012 lb/MMBtu heat input	3-hour average based on the results of compliance source testing	7/1/14

 

The SNCR contingency is included with BART in the event that new low NO_x burners with modified overfire air cannot achieve 0.23 lb/MMBtu heat input. The Department also recommends a Phase 2 NO_x emission reduction to 0.07 lb/MMBtu heat input (30-day rolling average) based on installation of a SCR or equivalent by July 1, 2017. This additional control requirement is recommended in order to minimize Boardman’s NO_x emissions to ensure that reasonable progress is being made to meet the regional haze goals for Class I Wilderness Areas and National Parks and to further improve the air quality and scenic vistas in the Columbia River Gorge National Scenic Area. It is estimated that the capital cost of Phase 1 will be 280 million dollars with an annualized cost of 40.3 million dollars per year (2007 dollars). Phase 2 for NO_x will add an additional capital cost of 191 million dollars with an annualized cost of 23.1 million dollars (2007 dollars). The other option for PGE is to install the low NO_x burners but not the FGD and SCR systems, and then shut the plant down in 2020. See www.deq.state.or.us/aq/haze/pge.htm

 

KU Agrees to Add SCR and FGD at E. W. Brown 3

 

Kentucky Utilities has agreed to pay $1.4 million in civil penalties and spend about $135 million on new pollution-control equipment in a settlement with federal regulators over pollution from the E.W. Brown Generating Station. “Today’s settlement sets the most stringent limit for nitrogen oxide emissions ever imposed in a federal settlement with a coal-fired power plant,” Catherine McCabe, acting assistant administrator for the EPA’s Office Enforcement and Compliance Assurance, said in a statement. Under the settlement, KU is to install new pollution-control equipment to cut combined SO₂ and NO_x emissions by more than 31,000 tons annually. That would be a reduction of 90 percent from 2007 levels, according to regulators. The utility also must install controls to lower particulate emissions by about 1,000 tons per year. The new pollution-control equipment will be installed over the next four years on E.W. Brown 3. The utility also agreed to give up its excess NO_x and SO₂ allowances once the new pollution-control equipment is installed.

 

The terms of the consent decree include:

 

·      By no later than December 31, 2012, Kentucky Utilities shall install an SCR at Brown 3. The SCR will be run year round and maintain a 30-day rolling average emission rate of no greater than 0.070 lb/MMBtu.

 

·     Beginning 30 days from entry of this Consent Decree, Kentucky Utilities shall continuously operate the existing low NO_x burners and over-fire air at Brown.

 

·     At least 180 days prior to commencing operation of the SCR, and no later than June 30, 2012, Kentucky Utilities shall submit to EPA for review and approval a plan for the placement and installation of NO_x CEMS at Brown 3 for the purpose of measuring NO_x emissions from only Brown 3 and not Brown 1 and 2.

 

·     Beginning no later than December 31, 2010, Kentucky Utilities shall install a FGD at Brown 3. The FGD will achieve and maintain a 30-day rolling average emission rate for SO₂ of no greater than 0.100 lb/MMBtu or a 30-day rolling average SO₂ removal efficiency of not lower than 97 percent.

 

·     Beginning thirty (30) days after entry of this Consent Decree and continuing thereafter, Kentucky Utilities shall continuously operate the ESP at Brown 3 to maximize PM emission reductions at all times when the Unit is in operation. The ESP will achieve a PM emission rate no greater than 0.030 lb/MMBtu. Compliance with the 0.030 lb/MMBtu emission rate shall be demonstrated by stack tests.

 

·     Kentucky Utilities shall install, correlate, operate, and maintain a PM CEMS at the common stack servicing Brown 3. The PM CEMS shall be comprised of (a) a continuous particle mass monitor that measures particulate matter concentrations, directly or indirectly, on an hourly average basis and (b) a CO₂ monitor used to convert the concentration to units of lb/MMBtu.

 See http://www.usdoj.gov/enrd/ConsentDecrees/994_4_Kentucky_Utilities_Company_CDFinal.pdf for more details.

 

Justice Dept. Sues Westar Jeffrey over NSR Projects

 

The EPA has filed a lawsuit accusing Westar Energy Inc. of violating federal air quality laws at one of its coal-fired power plants. The federal lawsuit, filed Wednesday in Kansas City, KS, says Westar made major modifications to the Jeffrey Energy Center in St. Marys, Kansas over the past decade but didn’t update the plant’s pollution control equipment.

 

Westar Energy, Inc. issued this response to the EPA/U.S. Department of Justice lawsuit:

 

“We have known for more than six years, and have even publicly disclosed, that the Department of Justice at some point might file a lawsuit. We are good environmental stewards, and that is why over the last several years we have invested nearly $500 million to remove up to 90 percent of the very emissions that the EPA has targeted with its complaint. We also expect to invest more than $1 billion in additional equipment over the next five years.”

 

PA Judge Tosses State Mercury Rule

 

A judge threw out a regulation that made Pennsylvania the first major coal mining state to require coal-fired power plants to cut mercury emissions beyond levels set by federal standards. Commonwealth Court Judge Dan Pellegrini ruled Thursday that the rule is unlawful, invalid and unenforceable. The two year old rule was challenged by PPL Corp. PPL spokesman George Lewis said the company was worried about wasting millions of dollars on pollution control equipment to meet a state standard that may be erased or preempted once the U.S. Environmental Protection Agency writes a federal regulation to control mercury. “It really for us is a question of certainty and knowing that the upgrades we make, the technology we put in our coal plants, will be the right ones…and not an interim measure that we’ll have to take out,” Lewis said. Governor Ed Rendell’s administration issued a statement that said it was deciding whether to appeal. It warned that Pellegrini’s decision threatened to derail plans by a number of coal-fired power plants to install pollution control equipment.

 

Up and Running

 

Essar Steel Algoma Inc.'s  announced that the No. 7 blast furnace has started up a new, permanent baghouse. The baghouse, was installed largely  as the result of community complaints about particulate issues. Essar Steel Algoma agreed to spend about Canadian $25 million ($20.1 million) to install the baghouse under the terms of an agreement to control air-quality emissions in the Sault Ste. Marie area.

 

 Richmond Power & Light’s new baghouse is now operational. The company announced that by injecting limestone they are able to scrub out 10 to 15 percent of sulfur dioxide emissions, 10 percent of nitrous oxide emissions and 70 percent of mercury emissions. They expect to save ratepayers as much as $1M per year due to the reduced need for emission credits.

                                            

Find us at our web address; www.mcilvainecompany.com Email us at; editor@mcilvainecompany.com

 

 

FGD & DeNOx NEWSLETTER IS PUBLISHED MONTHLY

Publisher:  R. W. McIlvaine;  Managing Editor:  Marilyn McIlvaine

Editor: Jeanene Dueber 

COPYRIGHT 2009

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