NEWS RELEASE                                                                                                    APRIL 20115

World NOx Market to Reach $21 Billion This Year

The market for NOx control systems, reagents and catalyst will exceed $21 billion this year according to the McIlvaine Company in its continually updated NOx Control World Market.

NOx Revenues - $ Millions     

   Subject      2015  
 Catalyst    585
 Reagent    2,788
 SCR    17,376
Total 20,749

The equipment market will reach a peak next year and fall whereas the quantity of reagent and catalyst will steadily increase over the next five years.   Presently, the major market is China.  They are completing a program to retrofit over 400,000 MW of coal-fired boilers with SCR. When this is complete, the Chinese market will be mostly limited to new coal-fired boilers and industrial applications.

The market is growing in countries which traditionally have not enforced NOx control.  Ahlstom just received a large order for NOx control for boilers in Russia. The program in Eastern Europe is moving forward.

There are a variety of approaches to NOx control.  Selective catalytic reduction (SCR) is the most prolific.  Selective non-catalytic reduction (SNCR) is mostly used in industrial installations.  The market for NOx control for gas turbines is growing due to the many new installations underway in the U.S.

One new technology which could significantly change the industry is the catalytic filter.  NOx and particulate are removed in one device operating at 850oF.  An efficient heat exchanger can then be used to extract heat from the clean gas and improve boiler efficiency. Haldor Topsoe has announced construction of a new facility in Houston, TX to produce these elements. The Filtration Group has supplied their elements to many incinerators, combustors and glass plants in Europe and the U.S.

For more information on N035 NOx Control World Market, click on:

NEWS RELEASE                                                                                                    APRIL 2015

$800 Million Cartridge Market in Food and Beverage By 2020

The market for cartridges in the food and beverage industry will rise to $800 million in 2020 in actual dollars taking into account projected inflation. The market in 2010 dollars will be $670 million according to the latest forecasts in Cartridge Filters: World Market published by the McIlvaine Company.

$ Millions 

   World Region      2019  
 Total * 622
 Africa  27
 CIS  27
 East   Asia  206
 Eastern   Europe  14
 Middle   East  32
 NAFTA  130
 South   & Central America  51
 West   Asia  46
Western Europe      89

                                                                                              * in 2010 U.S. dollars

Nearly half the revenues will be derived from sales to improve food and beverage product.  These process filters are frequently replaced.  The other 50 percent of the revenues will come from the treatment of water and wastewater associated with processes.  Specific applications are found in:

  • Beer
  • Wine
  • Distilled Spirits
  • Soft Drinks
  • Fruit Juices
  • Baby Foods
  • High Fructose Corn Syrup
  • Gelatin
  • Edible Oils
  • Flavors and Fragrances

Membrane cartridges compete with depth cartridges using diatomaceous earth and other filter aids.

East Asia is the fastest growing market. By 2019, sales of cartridges for food and beverage will exceed $200 million.  NAFTA and Western Europe are net exporters of processed food and beverages. So filter use is relatively high in proportion to the food consumed in the two regions.

Pall, Clarcor, 3M, GE and Eaton are major cartridge suppliers to the food industry based in the U.S.

For more information on Cartridge Filters: World Market, click on:

NEWS RELEASE                                                                                                                APRIL 2015

Fabric Filter Market to Expand Rapidly Due to Precipitator Conversion

The market for fabric filter systems will exceed $9 billion this year according to the latest forecast in N021 World Fabric Filter and Element Market.

($ Millions)     

   World Region      2015  
Total  9,326
Africa  264
CIS  264
East   Asia  4,751
Eastern   Europe  222
Middle   East  263
NAFTA  1,499
South   & Central America  468
West   Asia  901
Western   Europe  694

Over the next ten years, the market will expand at close to double-digit rates due to a number of power plants which will remove the internals of their electrostatic precipitators and replace them with filter bags.  Power plants in the U.S., Italy, Russia, Chile and South Africa have already embarked on this program. Each of these projects is tracked in 42EI Utility Tracking System.

Tough new regulations requiring outlet particulate limits of less than 5 mg/Nm3 are the driving forces behind these retrofits.  The new regulations in China will create the largest potential for a single country.  Recent Chinese designs have incorporated dry scrubbing and particulate control with fabric filters to reach low SO2 and particulate levels.

Power plants are being provided with a free system to help them make the needed decisions Power Plant Systems and Components.

The power plant decision makers are aided by the equivalent of a GPS route map to travel back and forth between regulatory, technology and process decision trees.

Hot Gas Filtration Global Decisions Positioning System™ (GdPS)

An American Filtration Society conference on April 29th will include a session conducted by McIlvaine on the hot gas filter options

For more information on: World Fabric Filter and Element Market, click on:

NEWS RELEASE                                                                                                    APRIL 2015

Difficult Complex Decisions For Coal-fired Power Plant Operators

Changing fuel prices, government regulations and technology all combine to make decision making difficult for operators and developers of coal-fired power generation facilities around the world.

Power plant designers in developing countries face new local environmental regulations plus additional requirements stipulated by lenders such as the World Bank.  In the developed world, the regulations keep getting tougher. So operators must not only deal with the current round of upgrades but the next round as well.

Recent extreme changes in the price of oil and gas need to be factored into decisions. The price and availability of coal needs to be forecast. The option to burn gas in an existing coal-fired boiler or to retire the boiler and replace it with a more efficient gas turbine combined cycle power plant is relevant for older coal-fired power plants subject to expensive environmental upgrades.

The most difficult challenge is to keep up with all the new technology options.  Stringent mercury regulations have resulted in the following choices:

  • Activated carbon injection ahead of the existing precipitator
  • Activated carbon injection ahead of a new fabric filter
  • Non-carbon sorbents
  • Halogen addition to the fuel and capture of oxidized mercury in the scrubber
  • SCR catalyst with higher conversion rate of elemental mercury to the oxidized form
  • Post scrubber non-regenerative  mercury capture module
  • Mercury CEMS or sorbent traps
  • Use of mercury CEMS for double duty including compliance and process control (other option is a 2nd CEMS)

The technology to capture SO2 has constantly expanded and improved since the first commercial installation in 1968 at Union Electric in St Louis.  Options now include:

  • Limestone spray tower or tray tower
  • Lime scrubbing with smaller scrubber size and flow
  • Spray drier with lime slurry
  • Spray drier with lime slurry and direct sorbent injection upstream for higher efficiency
  • Circulating dry scrubbers (CDS) with either fluid bed (CFB) or gas suspension absorber (GSA)
  • Direct sorbent injection (DSI) with sodium,  lime or even finely powered limestone
  • Adsorption on activated carbon and sulfuric acid generation
  • Absorption with ammonia and fertilizer production
  • Absorption with amines and sulfur production
  • Catalytic conversion of SO2 and production of sulfur products
  • Hot gas catalytic filter with DSI with either high surface area hydrate or finely ground limestone injected in the furnace or both

The requirements for particulate removal are more stringent everywhere. In Russia, China, South Africa, the U.S. and many other countries existing precipitators are going to be upgraded or replaced to meet limits as low as 5 mg/Nm3.  Options include:

  • New larger precipitator
  • Hybrid with one field replaced with bags
  • Complete retrofit of precipitator shell with bags
  • New fabric filter for 350oF
  • New 850oF ceramic fabric filter with more efficient heat exchanger for improved boiler efficiency
  • Wet precipitator with initial capture in baghouse or dry precipitator
  • Wet precipitator with only a venturi scrubber ahead of it for particulate control and SO2 capture

NOx control options include:

  • Low NOx burners
  • Combustion modifications
  • Selective catalytic reduction (SCR)
  • Selective non-catalytic reduction (SNCR)
  • Ozone
  • Hydrogen Peroxide
  • Various combinations of the above and various control locations e.g. tail end SCR after the scrubber

The power plant decision maker has to keep moving back and forth among decision trees as he makes the above decisions. Some limit fuel selection. Some present solid waste problems. Some contribute to water pollution problems.

This complex set of tasks has been organized into a system: 44I Power Plant Air Quality Decisions.  This system is free of charge to any of the world’s power plant operators and by yearly subscription to others. The operating system is the 4As.  This includes Alerts, Answers, Analysis and Advancement.  The answers are contained in a Decision Orchard.  The complex navigation is greatly simplified by Global Decisions Positioning Systems™ (GdPS).  Here are two examples:

        SO3 Fast Track Global Decisions Positioning System™ (GdPS)

        Hot Gas Filtration Global Decisions Positioning System™ (GdPS)

NEWS RELEASE                                                                                                    APRIL 2015

Air Filtration Market Will Exceed $7 Billion This Year

The market for filters for indoor air and gas turbine air inlets will exceed $7 billion in 2015.   The biggest driver in Asia is the increased use in residences and commercial buildings to prevent pollutants in the ambient outdoor air from entering the internal environment.  This is one of the conclusions reached in the latest McIlvaine forecasts in N022 Air Filtration and Purification World Market.

Air Filter Revenues ($ Millions)

   World Region      2015  
 Total  7,158
 Africa  183
 CIS  278
 East   Asia  2,115
 Eastern   Europe  130
 Middle   East  264
 NAFTA  2,283
 South   & Central America  277
 West   Asia  279
 Western   Europe  1,349

The big driver in the U.S. is the expansion of the gas turbine market.  Most of the additional U.S. power generation capacity will come from gas turbine plants as identified in: 59EI Gas Turbine and Combined Cycle Supplier Program.

The market is expanding substantially due to product upgrades and price per unit increases.  It has been learned that gas turbine maintenance and downtime can be reduced with the use of high efficiency (HEPA) filters as opposed to medium efficiency filters.  These filters cost several times more, but are justified on a life cycle basis.

A unique new guide to these selections has been created in Gas Turbine Air Treatment Global Decisions Positioning System™ (GdPS).

An American Filtration Society conference on April 28th will include a session conducted by McIlvaine on the filter options

For more information on these services contact: This email address is being protected from spambots. You need JavaScript enabled to view it.