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In the several years that have elapsed since then, much has happened in the coal-fired power plant industry and its attempts to control air pollution from such plants. In addition, much else has happened and continues to happen in the overall U.S. and global economic, energy, and pollution control situations. Many different and interlaced factors, not only technological and economic, but also increasingly political, are affecting and often driving the discussions of present and future policies and plans.
There are two different pertinent economic and technical areas, which with the countries of the world (and the entire global economy) are currently struggling with and seeking solutions. These are energy supplies and the environmental consequences of exploiting those supplies.
Energy can be supplied from a number of different sources. Today, most of the world’s energy is derived from so-called “fossil fuels,” the products of millennia of decay of animal and vegetable matter. The three primary fossil fuels are crude oil, natural gas, and coal, and all three have been exploited vigorously.
Crude oil has several advantages in that it is liquid (usually) and is rather easily and economically transported around the globe and across land and sea. Crude oil is refined using known technologies to produce a number of different products, ranging from light gases to liquid fuels to heavy oils and asphalts. It is in high demand for its ease of use, number of applications, and unless there is some global political or economic upset, relatively low price. In 2008, the price of crude oil more than doubled in less than a year for no known physical or supply reasons except that developing countries, especially China and India, are using and seeking far greater quantities of oil than in the past. However, no sooner had crude oil prices peaked at close to $150/bbl than the price bubble burst and prices dropped to the current (early 2009) levels around $40/bbl.
Natural gas has one principal advantage: it is the cleanest burning of the fossil fuels. Its demand has increased as tougher environmental controls of power plants have moved many utilities and other power producers to either switch to natural gas or build new power plants that burn it. However, natural gas has one big disadvantage compared with crude oil; that is, it is gaseous. In addition, a unit of energy (such as a BTU or a joule) of a gas takes up much more space than a liquid. Transporting natural gas over large distances requires a much greater investment than that to transport an energy-equivalent quantity of crude oil. There are solutions, such as liquefying the gas with cold, pressure, or both for smaller-volume transport, and building power and other gas-using plants near gas fields. However, a lot of current natural gas is considered “stranded” in remote places like Siberia, and a lot of it is flared into the atmosphere.
Coal, the third fossil fuel, is important principally to date as a fuel for the generation of electric power. Being solid, it is not easily adapted for use as a transportation fuel unless it is chemically converted to a combustible gas or liquid; more later on so-called coal-to-liquid (CTL) technologies. Thus, coal is used today in the United States primarily for electrical power generation, and coal-fired power generation is the subject of this study and report.
Global energy supplies, until very recently, were exploited and used around the world with little concern about the future. Most usage has been in developed nations, and most conspicuously in the United States, which has about 5% of the global population but uses up to 35% of global energy supply. The world’s energy supplies are used in a number of different application areas, such as transportation, power generation, heating, etc. study goals and objectives.
The environmental consequences of burning fossil fuels were essentially ignored for many years from the start of the Industrial Revolution. Stories of the “dark satanic mills” of the British industrial midlands of the 19th century abound in literature. As the world’s population grew and demand for power and industrial goods grew, the effects of all this fossil fuel burning became more apparent from increased smog, respiratory problems, dying trees, acid rain, and other effects. It also caused increasingly political and economic considerations for governments, industry, and the public. These consequences show up in different ways, some obvious such as visible tailpipe and smokestack emissions, others less visible in the form of unseen toxic and other environmentally unfriendly gases and both liquid and solid wastes.
Now the problem of global warming is taking center stage, adding more urgency to the quest for new and/or better solutions to pollution from fossil fuel burning. One aspect of this overall global problem, that of control of air pollution from coal-fired power plants, is the focus and subject of this report.
For decades, the U.S. has relied on coal-fired electric-generating plants as the foundation of its central power system. Indeed, today more than half the electricity generated in the U.S. comes from burning coal. Coal is a very complex material. As we discuss later, fossil fuels vary depending on their geographical origin. Thus, there are different types of coal, crude oil, and natural gas, varying in chemical composition. “Coal” is a generic term for a great number of mixtures of often large and complex organic compounds, usually also containing metals and other contaminants. Burning coal generates many other emissions besides carbon dioxide (CO2) and water, the normal products of organic oxidation.
Because of these emissions, coal has received a lot of criticism as a power-generation fuel source because of its contribution to air pollution. Air emissions standards, constantly under study and discussion in universities, utilities, and government, have resulted in a re-evaluation of coal as a fuel source and the development of new technologies for reducing plant emissions. With deregulation of the utility market and the continual increase in the nation’s energy requirements, the need for cost-effective and environmentally compliant technologies also increases.
This report analyzes the trends and developments of the rapidly changing U.S. market for air pollution control technologies for coal-fired power plants. The report provides an overview of the coal-based power industry, including history, key regulations, types and characteristics of plant emissions, types of emission-control technologies, industry structure, and future trends. Market forecasts are included for equipment to control the current major air pollutants from coal-fired power plants.
This study focuses primarily in the United States but also includes some international observations, given the global nature of business and technology these days when no nation or region can operate without consideration of the rest of the world. However, our focus is on the United States.
During recent years, much emphasis has been placed on the development of air pollution control technologies that will allow the continued use of coal as an energy source while meeting the stringent requirements of the Clean Air Act Amendments (CAAA) of 1990 and subsequent legislation and regulations. The report is designed to provide information of a professional nature, and the technical data are dependent on the accuracy of data provided by manufacturers, researchers, and government sources that we covered in our research. We have sorted through, organized, and condensed information from a large amount of literature and other reference materials to compile this report. The report is not intended to be an endorsement of any energy source, company, or technology.
The report should be valuable and essential for vendors, research and development organizations, investors, and engineering and construction firms faced with complex business decisions involving the future directions of energy development. It will also prove to be valuable to government agencies, legislators, policymakers, and other stakeholders.
The report provides an analysis of the market for air pollution control technologies for both utility and non-utility coal-fired power plants. It includes technologies designed for retrofitting existing plants to meet new standards, as well as technologies for repowering existing facilities and for new plant construction. The report characterizes the types of air emissions associated with coal-based power systems and the key regulations that drive technology requirements. It evaluates the current R&D status and effectiveness of control technologies for sulfur dioxide (SO2), nitrogen oxides (NOx), particulate matter (PM), and so-called hazardous air pollutants (HAPs), or “air toxics,” with a primary emphasis at this time on mercury.
Since CO2 is not a toxic substance in the chemical and environmental control sense, it is not in the scope of this study even though there are current measures being taken to call it a pollutant for its greenhouse gas properties. We do discuss some of the current discussions regarding CO2 sequestration, but do not attempt to forecast such markets since they do not yet exist at this time.
The market analysis section in this report provides a detailed analysis and estimates of the markets in base year 2008 and 5-year market forecasts for 2013 for each major technology. Because of the extreme uncertainties in these times, both economic and political, we use a simple scenario analysis to estimate and forecast these markets. Any market estimates these days are speculative, and ours are no exception.
This report consists of eight narrative sections, of which this is the first, plus an appendix with a glossary of important terms.
The narrative and market analysis sections that follow are:
This report:
TABLE OF CONTENTS
Chapter-1: SUMMARY
SUMMARY TABLE U.S. MARKET FORECAST FOR AIR POLLUTION CONTROL TECHNOLOGIES FOR COAL-FIRED POWER PLANTS: OPTIMISTIC SCENARIO, THROUGH 2013 ($ MILLIONS) |
SUMMARY FIGURE U.S. MARKET FORECAST FOR AIR POLLUTION CONTROL TECHNOLOGIES FOR COAL-FIRED POWER PLANTS: OPTIMISTIC SCENARIO, THROUGH 2013 ($ MILLIONS) |
Chapter-2: COAL-BASED POWER INDUSTRY OVERVIEW
COAL OVERVIEW |
INDUSTRIAL PROCESSES IN THE COAL-BASED ELECTRIC-GENERATION INDUSTRY |
STEAM TURBINE ELECTRICITY GENERATION |
Tangentially Fired Boilers |
Wall-Fired Boilers |
Single Wall Boilers |
Opposed Wall Boilers |
Cell Burner Boilers |
Vertically Fired Boilers |
Cyclone-Fired Boilers |
Stoker-Fired Boilers |
Fluidized-Bed Combustors |
Atmospheric FBC |
Pressurized FBC |
INTEGRATED COAL-GASIFICATION COMBINED CYCLE |
COGENERATION SYSTEMS |
COAL TRANSPORT AND PROCESSING |
AIR POLLUTION FROM AND ASSOCIATED WITH COAL-BASED POWER GENERATION SYSTEMS |
EMISSIONS DATA |
SULFUR DIOXIDE |
TABLE 1 NATIONAL AVERAGE SO2 CONCENTRATION, 1990–2007 (PPM) |
NITROGEN OXIDES |
TABLE 2 NATIONAL AVERAGE NOX CONCENTRATION, 1980–2007 (PPM) |
PARTICULATE MATTER |
TABLE 3 NATIONAL AVERAGE PM2.5 CONCENTRATION, 2000–2007 (PPM) |
TABLE 4 NATIONAL AVERAGE PM10 CONCENTRATION, 1990–2007 (PPM) |
CARBON MONOXIDE |
TABLE 5 NATIONAL AVERAGE CO CONCENTRATION, 1980–2007 (PPM) |
CARBON DIOXIDE |
HAZARDOUS AIR POLLUTANTS (AIR TOXICS) |
Chapter-3: AIR POLLUTION/EMISSION CONTROL TECHNOLOGIES
FLUE GAS DESULFURIZATION |
WET FGD |
DRY SORBENT INJECTION |
PRODUCTION OF SULFURIC ACID |
NOX EMISSIONS CONTROL TECHNOLOGIES |
COMBUSTION CONTROL TECHNOLOGIES FOR NOX EMISSIONS CONTROL |
Operational Modifications to Optimize NOx Reduction |
Overfire Air |
Low-NOx Burners |
Reburn and Gas Co-Firing |
Combined Combustion Controls |
POST-COMBUSTION NOX CONTROLS |
Selective Catalytic Reduction |
Selective Noncatalytic Reduction |
PARTICULATE MATTER REDUCTION |
ELECTROSTATIC PRECIPITATORS |
Dry ESP |
Wet ESP |
Membrane ESP |
FABRIC FILTERS (BAGHOUSES) |
MECHANICAL SHAKER-TYPE FABRIC FILTERS |
REVERSE-AIR FABRIC FILTERS |
REVERSE PULSE-JET CLEANED FABRIC FILTERS |
MULTIPOLLUTANT CONTROL SYSTEMS |
MERCURY CONTROL TECHNOLOGIES |
TABLE 6 EFFECTIVENESS OF MERCURY CONTROL TECHNOLOGIES |
TABLE 7 MERCURY CONTROL TECHNOLOGY COSTS |
CARBON SEQUESTRATION TECHNOLOGIES |
CARBON SEQUESTRATION TECHNOLOGIES (CONTINUED) |
CO2 SEPARATION AND CAPTURE |
SEQUESTRATION IN THE OCEAN |
SEQUESTRATION ON LAND IN GEOLOGIC FORMATIONS |
SEQUESTRATION IN TERRESTRIAL ECOSYSTEMS |
COAL PROCESSING AND CONVERSION |
ADVANCED POWER-GENERATING TECHNOLOGIES |
TABLE 8 EFFECTIVENESS OF ADVANCED POWER-GENERATION TECHNOLOGIES |
PULVERIZED COAL PLANTS |
LOW-EMISSION BOILER SYSTEM |
FLUIDIZED-BED COMBUSTION |
Pressurized Fluidized-Bed Combustion |
INTEGRATED GASIFICATION COMBINED CYCLE |
COAL TO LIQUIDS TECHNOLOGY |
U.S. PATENT ANALYSIS |
TABLE 9 U.S. AIR POLLUTION CONTROL PATENTS FOR COAL-FIRED POWER PLANTS, 2002–2007 (NUMBER) |
FGD TECHNOLOGY PATENTS |
NOX-CONTROL TECHNOLOGY PATENTS |
PARTICULATE AND MERCURY CONTROL TECHNOLOGY PATENTS |
CO2 CAPTURE AND STORAGE PATENTS |
Chapter-4: AIR POLLUTION CONTROL MARKET ANALYSES AND FORECASTS
AIR POLLUTION CONTROL MARKET ANALYSES AND FORECASTS |
OVERALL MARKET ANALYSIS |
TABLE 10 U.S. MARKET FORECAST FOR AIR POLLUTION CONTROL TECHNOLOGIES FOR COAL-FIRED POWER PLANTS: MOST LIKELY SCENARIO, THROUGH 2013 ($ MILLIONS) |
FIGURE 1 U.S. MARKET FORECAST FOR AIR POLLUTION CONTROL TECHNOLOGIES FOR COAL-FIRED POWER PLANTS: MOST LIKELY SCENARIO, 2008 AND 2013 ($ MILLIONS) |
TABLE 11 U.S. MARKET FORECAST FOR AIR POLLUTION CONTROL TECHNOLOGIES FOR COAL-FIRED POWER PLANTS: OPTIMISTIC SCENARIO, THROUGH 2013 ($ MILLIONS) |
FIGURE 2 U.S. MARKET FORECAST FOR AIR POLLUTION CONTROL TECHNOLOGIES FOR COAL-FIRED POWER PLANTS: OPTIMISTIC SCENARIO, THROUGH 2013 ($ MILLIONS) |
TABLE 12 U.S. MARKET FORECAST FOR AIR POLLUTION CONTROL TECHNOLOGIES FOR COAL-FIRED POWER PLANTS: PESSIMISTIC SCENARIO, THROUGH 2013 ($ MILLIONS) |
FIGURE 3 U.S. MARKET FORECAST FOR AIR POLLUTION CONTROL TECHNOLOGIES FOR COAL-FIRED POWER PLANTS: PESSIMISTIC SCENARIO, 2008 AND 2013 ($ MILLIONS) |
FLUE GAS DESULFURIZATION |
TABLE 13 U.S. MARKET FORECAST FOR COAL-FIRED POWER PLANT FGD SCRUBBERS, THROUGH 2013 ($ MILLIONS) |
FIGURE 4 U.S. MARKET FORECAST FOR COAL-FIRED POWER PLANT FGD SCRUBBERS, 2008 AND 2013 ($ MILLIONS) |
NOX CONTROLS |
TABLE 14 OVERALL U.S. MARKET FORECAST FOR COAL-FIRED POWER PLANT NOX CONTROLS, THROUGH 2013 ($ MILLIONS) |
FIGURE 5 OVERALL U.S. MARKET FORECAST FOR COAL-FIRED POWER PLANT NOX CONTROLS, 2008 AND 2013 ($ MILLIONS) |
Combustion NOx Controls |
TABLE 15 U.S. MARKET FORECAST FOR COMBUSTION-BASED NOX CONTROLS, THROUGH 2013 ($ MILLIONS) |
FIGURE 6 U.S. MARKET FORECAST FOR COMBUSTION-BASED NOX CONTROLS, 2008 AND 2013 ($ MILLIONS) |
TABLE 16 U.S. MARKET FORECAST FOR LOW-NOX BURNER NOX CONTROLS, THROUGH 2013 ($ MILLIONS) |
FIGURE 7 U.S. MARKET FORECAST FOR LOW-NOX BURNER NOX CONTROLS, 2008 AND 2013 ($ MILLIONS) |
TABLE 17 U.S. MARKET FORECAST FOR OVERFIRE AIR NOX CONTROLS, THROUGH 2013 ($ MILLIONS) |
FIGURE 8 U.S. MARKET FORECAST FOR OVERFIRE AIR NOX CONTROLS, 2008 AND 2013 ($ MILLIONS) |
Post-Combustion NOx Controls |
TABLE 18 U.S. MARKET FORECAST FOR POST-COMBUSTION BASED NOX CONTROLS, THROUGH 2013 ($ MILLIONS) |
FIGURE 9 U.S. MARKET FORECAST FOR POST-COMBUSTION BASED NOX CONTROLS, 2008 AND 2013 ($ MILLIONS) |
TABLE 19 U.S. MARKET FORECAST FOR SCR NOX CONTROLS, THROUGH 2013 ($ MILLIONS) |
FIGURE 10 U.S. MARKET FORECAST FOR SCR NOX CONTROLS, 2008 AND 2013 ($ MILLIONS) |
TABLE 20 U.S. MARKET FORECAST FOR SELECTIVE NON-CATALYTIC REDUCTION NOX CONTROLS, THROUGH 2013 ($ MILLIONS) |
FIGURE 11 U.S. MARKET FORECAST FOR SELECTIVE NON-CATALYTIC REDUCTION NOX CONTROLS, 2008 AND 2013 ($ MILLIONS) |
PARTICULATE AND MERCURY CONTROL |
TABLE 21 OVERALL U.S. MARKET FORECAST FOR PARTICULATE AND MERCURY CONTROLS, THROUGH 2013 ($ MILLIONS) |
FIGURE 12 OVERALL U.S. MARKET FORECAST FOR PARTICULATE AND MERCURY CONTROLS, 2008 AND 2013 ($ MILLIONS) |
ELECTROSTATIC PRECIPITATORS |
TABLE 22 U.S. MARKET FORECAST FOR ESPS, THROUGH 2013 ($ MILLIONS) |
FIGURE 13 U.S. MARKET FORECAST FOR ESPS, 2008 AND 2013 ($ MILLIONS) |
FABRIC FILTERS (BAGHOUSES) |
TABLE 23 U.S. MARKET FOR FABRIC FILTERS (BAGHOUSES), THROUGH 2013 ($ MILLIONS) |
FIGURE 14 U.S. MARKET FOR FABRIC FILTERS (BAGHOUSES), 2008 AND 2013 ($ MILLIONS) |
SPRAY COOLERS |
TABLE 24 U.S. MARKET FORECAST FOR SPRAY COOLERS, THROUGH 2013 ($ MILLIONS) |
FIGURE 15 U.S. MARKET FORECAST FOR SPRAY COOLERS, 2008 AND 2013 ($ MILLIONS) |
MERCURY CONTROL SYSTEMS |
TABLE 25 U.S. MARKET FORECAST FOR MERCURY CONTROLS, THROUGH 2013 ($ MILLIONS) |
FIGURE 16 U.S. MARKET FORECAST FOR MERCURY CONTROLS, 2008 AND 2013 ($ MILLIONS) |
Chapter-5: INDUSTRY STRUCTURES AND COMPETITIVE ANALYSIS
ELECTRIC POWER INDUSTRY STRUCTURE |
UTILITY POWER PRODUCERS |
NON-UTILITY POWER PRODUCERS |
AIR POLLUTION CONTROL TECHNOLOGY INDUSTRY |
INDUSTRY STRUCTURE |
SOME INTERNATIONAL ASPECTS |
Chapter-6: GOVERNMENT, REGULATORY, AND PUBLIC ISSUES
REGULATIONS |
FEDERAL LEGISLATION ON AIR POLLUTION AND CONTROL |
CLEAN AIR ACT AMENDMENTS OF 1990 |
Acid Rain Program |
SO2 Reduction Program |
NOx Reduction Program |
TABLE 26 TITLE IV COAL-FIRED BOILER NOX EMISSION LIMITS (LB./MMBTU) |
National Ambient Air Quality Standards |
New Source Review and New Source Performance Standards |
State Implementation Plans |
National Emission Standards for Hazardous Air Pollutants |
MORE RECENT EPA REGULATORY ACTIONS |
NOx SIP Call |
Section 126 Petitions |
Revised Ozone NAAQS |
PM2.5 NAAQS |
Regional Haze Rulemaking |
RESOURCE CONSERVATION AND RECOVERY ACT |
EMERGENCY PLANNING AND COMMUNITY RIGHT-TO-KNOW ACT |
NATIONAL ENVIRONMENTAL POLICY ACT |
ENERGY POLICY ACT OF 2005 |
ELECTRIC POWER INDUSTRY DEREGULATION |
STRANDED COSTS |
ELECTRIC POWER MARKETERS |
DEREGULATION AND ENVIRONMENTAL CONCERNS |
CURRENT REGULATORY ISSUES |
CLEAN AIR MERCURY RULE |
CLEAN AIR INTERSTATE RULE |
TIGHTER LEAD EMISSIONS STANDARDS |
POWER PLANT POLLUTION CONTROLS - LOOSER OR TIGHTER? |
PUBLIC PERCEPTIONS AND ISSUES |
Chapter-7: COMPANY PROFILES
ADA ENVIRONMENTAL SYSTEMS |
ALSTOM |
THE BABCOCK & WILCOX CO. |
BURNS & MCDONNELL ENGINEERING CO. |
CALGON CARBON CORP. |
CORMETECH, INC. |
CROLL-REYNOLDS CO. |
CLYDE BERGEMANN EEC |
DONALDSON CO., INC. |
DUCON TECHNOLOGIES, INC. |
ELECTRIC POWER RESEARCH INSTITUTE, INC. |
FARR AIR POLLUTION CONTROL |
FILTERSENSE |
FLEX-KLEEN DIVISION, METRO-PRO CORP. |
FOSTER-WHEELER, LTD. |
FUEL TECH, INC. |
HAMON RESEARCH-COTTRELL, INC. |
JOHN ZINK COMPANY, LLC |
KBR, INC. |
MEMBRANE TECHNOLOGY AND RESEARCH, INC. |
MICROPUL |
NATIONWIDE BOILER, INC. |
NORIT AMERICAS, INC. |
RJM CORP. |
SARGENT & LUNDY, LLC |
SIEMENS ENVIRONMENTAL SYSTEMS AND SERVICES |
WAHLCO, INC. |
APPENDIX: GLOSSARY OF IMPORTANT TERMS, ABBREVIATIONS, ACRONYMS, ETC. |
GLOSSARY OF IMPORTANT TERMS… |
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