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William J. Morris
Manager, Particulate Systems
Hamon Research-Cottrell, Inc.
Somerville, New Jersey, USA
July 2002
The North American air pollution control market continues to evolve in response
to new and changing environmental regulations, new technologies, and even some new
applications of proven technologies. Some of the future changes expected in the
environmental regulations include tighter emissions regulations on SO2, NOx, PM-2.5,
Mercury control and air toxics such as lead, and cadmium.
As regulations change and markets react, Hamon Research-Cottrell, Inc. (HR-C)
is also continually refining and upgrading product offerings. HR-C has been very
successful in the North American market in the past two (2) years with numerous
contracts for DeNOx Selective Catalytic Reduction (SCR), pulse jet fabric filters and
rigid discharge electrode ESPs. To provide a more complete product line of air pollution
control technologies, and to address this changing marketplace, HR-C has recently
included an additional type of lime spray dryer absorber for Dry Flue Gas
Desulfurization (DFGD), new Wet Electrostatic Precipitator (WESP) technologies and
single tower Insitu Forced Oxidation Wet Flue Gas Desulfurization (IFO-WFGD)
systems. We have accomplished this expansion through a series of acquisitions, joint
venture partnerships, licenses and new applications of existing technologies.
U.S regulations can be found in different forms. In 1970, the U.S. Environmental
Protection Agency (EPA) began regulating “criteria air pollutants” with the passage of
the Clean Air Act (CAA). Criteria air pollutants are those that can injure health, harm the
environment and cause property damage. In 1990, the CAA was revised to reduce acid
air pollutants, considered to be connected to “acid rain”. Part of the regulations that
resulted includes a New Source Review (NSR). In a very controversial move, the
USEPA is now targeting utilities that did upgrades on their plants during the last 10
years without installing additional air pollution control (APC).
The US air pollution regulations are complicated and very specific to industries
and applications. Below are some current general guidelines for each of the major air
pollutants.
SO2 Emissions – The U.S CAA, Title IV, 1990, required utilities to achieve SO2
emission levels of 520 ng/J (1.2 lb /million BTU) by 2000. The U.S. utilities had
several options:
• Switch to lower sulfur fuels
• Blend current coal with lower sulfur fuel
• Install FGD systems
• Purchase or trade SO2 allowances –currently trading at $ 172 US.
Switching and blending fuels was the main strategy of 62 % (162 of 261) of the
affected units.
Particulate Emissions – The U.S CAA, Title IV, 1990, as identified in code of
Federal Regulations 40 CFR 60.42, also required utilities to achieve particulate
emission levels of 13 ng/J (0.015 lb/million BTU) by 2000. The U.S. utilities had
several options here also:
• Switch to lower ash fuels
• Blend current coal with lower ash fuel
• Install or upgrade particulate control systems
• Derate or retire units.
In response, many particulate systems were upgraded and older units were
retired.
In 1997, additional changes were made to the CAA to revise air quality
standards for ground level ozone (smog) and fine particulate matter (haze). The
new standards for particulate were for particulate matter less than 2.5 micron
(PM-2.5). These were 15 µg/m3 and 65 µg/m3 for annual and 24 hour standards.
These size specific particulate matter standards are now being observed in the
specifications for new air pollution control equipment.
NOx Emissions – The U.S CAA, Title IV, 1990, required utilities to achieve NOx
emission rates of between 86 and 340 ng/J (0.20 to 0.75 lb /million BTU) by
2000. The U.S. utilities again had several options:
• Combustion modifications
• Low NOx burners
• Install SCR or SNCR systems
• Purchase or trade NOx allowances –recent averages are $ 4,660
US (2002) and $ 4,800 US (2003).
The North American air pollution control market (essentially the U.S and Canada)
continues to evolve in response to these new and changing environmental regulations,
new technologies, and new applications of proven technologies. Some of the future
changes expected in the environmental regulations include additional restrictions on
PM-2.5, mercury emissions and air toxics such as lead. Below are shown some industry
projections of the current and future market for various air pollution control technologies.
- Electrostatic Precipitators
The projected total ESP market for 2002 through 2004 is shown in Table 1.
Table 1
ESP Market Breakdown ($ millions U.S)
- Fabric Filters
The projected total Fabric Filter (FF) market for 2002 through 2004 is shown in
Table 2.
Table 2
FF Market Breakdown ($ millions U.S)
While many power producers are concentrating on SCR for NOx reductions, the
California energy situation in 2001 also has produced a renewed interest in new coal
fired plants. However, PM-2.5 and Hg control will probably not create new opportunities
until 2004. The aftermarket, including bag replacements and parts, is expected to be 41
to 42 % of the FF market through 2004. Increased use of pleated filter bags is expected
since more filter area can be put in smaller casings. The use of membrane type filter
media is also expected to increase as an enhancement for improved fine particle
control.
- Wet Scrubbers
The projected total Wet scrubber (WS) market for 2002 through 2004 is shown in
Table 3.
Table 3
WS Market Breakdown ($ millions U.S)
Slow market recovery is expected after the U.S. recession ends. As the
industries gain strength and Maximum Achievable Control Technology (MACT)
standards start to take hold, the market is expected to expand. In the incineration
market WS, may be favored over WESPs due to ability to operate at higher velocities.
- NOx Control
NOx Control (or DeNOx) is currently the dominant market in the U.S. air pollution
control industry. This situation is expected to continue through 2010. Several
regulations are providing the impetus for NOx controls. These include SIP, NSR, and Air
Toxics, as well as NAAQS, and Regional Haze regulations. The projected total NOx
control market for 2002 through 2004 is shown in Table 4.
Table 4
Total NOx Market Breakdown by Product ($ millions U.S)
SCRs for NOx control are currently the dominant product for DeNOx in the U.S.
air pollution control industry. SCRs will account for 80 to 90 % of the NOx market at
least through 2004. However, SNCR is expected to show the greatest growth over the
next few years, especially in the power generation segment. This situation is expected
to continue through 2010.
The projected total NOx control market by end user for 2002 through 2004 is
shown in Table 5.
Table 5
Total NOx Market Breakdown by End-Use ($ millions U.S)
Power generation utility boilers will account for 75-87 % of the SCR end user
market at least through 2004. Energy shortages, high natural gas prices and the Bush
administration’s current initiatives are driving resurgence in coal. As of 2002, over 40
new coal fired plants have been announced. Energy shortages are also leading to
increased activity in gas turbines where 15-18 GW have been forecast per year through
2004.
The FGD market can be easily divided into two (2) primary technologies, Wet
FGD and Dry FGD. The Total FGD market includes both Wet and Dry Flue Gas
Desulfurization systems. The projected total FGD market for 2002 through 2004 is
shown in Table 6-1.
Table 6-1
Total FGD Market Breakdown ($ millions U.S)
The wet vs. dry split of the Electric Utility FGD market for 2002 through 2004 is
shown in Table 6-2.
Table 6-2
Electric Utility FGD Orders ($ millions U.S)
Only 33 % of U.S. Utility plants have installed scrubbers. The first big wave in the
U.S. air pollution control market is for SCRs for DeNOx. The second wave will be
increases in FGD expenditures for SO2 control. Some of this is driven by the New
Source Review (NSR) standards currently being debated in Washington, D.C. Between
2002 and 2004, a mix of new units, retrofits and NSR required projects are expected. By
2004, a 39 % increase in the Utility market is expected over 2001 levels.
The wet vs. dry split of the Industrial and MSW markets for 2002 through 2004 is
shown in Table 6-3.
Table 6-3
Industrial & MSW Orders ($ millions U.S)
The Industrial FGD market is expected to post strong increases after 2002,
especially in the petroleum refinery area, which has a big potential for increase from
2002 to 2004. This is partly due to rising refinery profitability and partly due again to
NSR.
It is expected that Wet FGD will capture the majority of the total FGD market from
2002 to 2004 due to an expected surge in Utility and refinery retrofits. Dry FGD will still
be used in some new Utility and CFB boiler projects. Even though a limestone injected
fluid bed boiler could remove up to 80 % of the SOx in the flue gas, current regulations
typically require a dry FGD system to remove 90 % of the remaining SO2. A Dry FGD
system is also very effective at removing excess SO3 and H2SO4, which may be
generated by installation of an SCR for NOx control.
- PM-2.5 – During the last several years, this pending legislation has withstood
several judicial reviews. Epidemiological studies have also confirmed the health impacts
of PM-2.5. This issue really relates to ambient air quality. Stack emissions are only one
source of atmospheric concentrations of PM-2.5. Other sources are road dust,
automobile exhausts and acid condensation in the atmosphere. To reduce ambient
levels requires reductions in precursor chemicals such as SO2 and NOx as well as
primary particulates. Studies in the Eastern US have shown that as much as 50 % of
PM-2.5 actually consists of condensable sulfates, nitrates and ammonium.
The U.S. air pollution control industry will probably not see source specific
regulations for PM-2.5 until 2004-2005.
- Mercury – Clean Air Act, section 112, requires power plant reductions by 2007.
EPA Rules are currently being developed. Presently the high number of US lakes that
have fish consumption advisories due to mercury deposition will continue to put
regulatory pressure on this pollutant. If EPA does not act, then a hodgepodge of state
rules will emerge which will be difficult for companies with interstate operations. (Ref. 2)
A recent report (Ref.3) indicates that carbon injection is the most mature retrofit
technology available for mercury reductions. Full scale tests with carbon injection have
demonstrated 50-70 % mercury reductions on units with ESPs and as much as 90 % on
units with fabric filters for final particulate cleanup.
The initiative also includes a strategy for reducing greenhouse gas intensity by
18 % over the next ten years. Greenhouse gas intensity is the ratio of greenhouse gas
emissions to economic output. This goal is comparable to the average progress
required by the Kyoto Protocol.
Fabric filters – After over 50 years of use, fabric filters continue to evolve:
Reverse gas to Pulse jets
Short (3.7 to 4.9 m) to long (5.5 to 8 m) bags
Heavy synthetic felt 18 oz and composites
Self-supporting synthetic felts (higher burst pressure, lower shrinkage rates)
No bypass or limited bypass (temperature only)
Operation with Oil firing required
ESPs – These products are fairly mature. Current design trends would be:
Rigid discharge electrodes
Wide plate spacing – 400 mm typical
Variable plate spacing within unit
Larger and fewer Transformer-Rectifier sets
WFGD – Also a mature product but with some very recent enhancements:
Single tower IFO limestone systems.
Internal modifications (rings and shelves) for enhancement of L/G rates
WESPs or NH3 injection for H2SO4 mist elimination.
DeNOx – still a relatively recent APC technology. Industry is always searching for
an alternative to NH3 reagent.
Urea for generating ammonia gas
WESPs for SO3 control
HR-C is a full spectrum supplier of air pollution control equipment for both utility
and industrial markets. In addition, HR-C coordinates product designs and activities with
over 40 Hamon offices throughout the world. Many of these Hamon offices market air
pollution control products that have obtained local acceptance and address local
markets. At HR-C-US, we also try to provide air pollution control products, which
address our North American market. Listed below are our current products, several
recent activities and a summary of new products, which indicate the breath of our
efforts.
Entech – also in 2001, HR-C purchased the assets of Entech, an ESP and
WESP supplier with construction group.
UtoA – This technology is a joint venture with Walhco, Inc. to market and install
urea to ammonia systems as an alternative to inherently dangerous anhydrous
ammonia gas systems. Already used successfully at several SCR installation
sites. UtoA (or U2A) stands for Urea to Ammonia Conversion. UtoA is used as a
safer alternative for an Ammonia source for DeNOx products. UtoA is actually a
chemical process called hydrolyzation, creating ammonia from an aqueous
solution of urea under the presence of a heat source. The first commercial
operation was in July 2001 at Huntington Beach, California for AES. In
September 2001, HR-C completed successful testing of 2000 lb/hr unit at
Harrison Station in West Virginia for Allegheny Power.
It should be noted that the above projects account for over 7300 MW of NOx
control and 16,740 lb/hr of ammonia supplied.
SCR - HR-C has been very successful in the North American market in the past
two (2) years with numerous contracts for Selective Catalytic Reduction (SCR)
systems for NOx control on combustion units. A summary of recent projects is
shown below.
Summary
References
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Abbreviations