NEWS RELEASE                                                                                                    AUGUST 2014

Power Plant Ultrapure Water Market to Reach $35 Billion In 2015

There are three major water treatment processes in power plants: 

  •  Pure water for steam
  • Cooling water
  • Wastewater

The process for purifying water for steam generation is referred to as ultrapure water.  Power plants around the world will spend over $35 billion on new and existing ultrapure water systems in 2015. This is the prediction in McIlvaine Ultrapure Water: World Market.

                                            World Power Plant Ultrapure Water Costs  In 2015

Generation   Type

MW   (1000)


$    Millions

Consumable   and Repair Parts

$   Millions

Gas   turbine new




Gas   turbine existing




Coal-fired   power new




Coal-fired   power existing




Nuclear   new




Nuclear   existing








Coal-fired,  gas turbine combined cycle, nuclear and concentrated solar power plants all use the same technologies for purifying the water which is converted to steam to drive the electric generator.  The major difference is that only a portion of the power is derived from steam generation in gas turbine combined cycle plants. However, there is a unique additional need for ultrapure water in some gas turbine plants.  In dry hot climates, water is introduced through fogging nozzles to reduce the inlet air temperature to the turbine.

The system includes a series of processes starting with purification of the raw water. Particulate soluble species and gases are removed.  High purity is needed to avoid fouling in boiler tubes as well as high temperature corrosion. Treatment is required both for the new water entering the cycle and for the condensed steam.  Equipment requirements are filters, piping, pumps, valves, ion exchange or electrodeionzation units, feedwater heaters, deareators, degasifiers, condensers and instrumentation.

Coumsumables and repair parts include chemicals, seals, membranes, cartridges, pump and valve parts, sensors, I.E resins, nozzles, packing, etc.  Corrosion inhibitors and anti scalant chemicals are a significant portion of the total.

Due to the activity in Asia, the investment in ultrapure water systems for coal-fired power plants in 2015 will exceed that of nuclear and gas turbine combined cycle plants combined. For more information on Ultrapure Water: World Market, click on:

NEWS RELEASE                                                                                                    AUGUST 2014

Scrubber Market Veering From Hardware to Consumables

Dry scrubber capital investment will be just under $600 million in 2015. This is less than 10 percent of the total scrubber capital investment.  But behind these numbers is a new path for the industry. Dry scrubbing is a way to capture acid gases at lower capital cost than with absorbers.  However, purchasers face much higher reagent costs.  Limestone used in wet systems is a fraction of the $200/ton price of lime used in dry scrubbers.  These developments are tracked in the McIlvaine publication Scrubber/Adsorber/Biofilter World Markets.

($ Top of FormMillions)














 Dry   Scrubber






Sodium compounds are also used in both dry scrubbers and wet scrubbers. But the amount of sodium to reach 90 percent HCl or SO2 removal can be 50 percent higher with dry scrubbing or dry sorbent injection (DSI).

Dry sorbent injection in effect eliminates any scrubber capital cost.  The sorbent is injected into duct ahead of the particulate collector. It reacts with the acid gases to form compounds such as calcium chloride or calcium sulfate. These compounds are then captured in the particulate collector.

One new approach with lots of promise is catalytic filtration with DSI.  All the pollutants are captured at 850oF.  The hot clean gas can then be directed through an efficient heat exchanger and substantially improve process efficiency. Glass plants, biomass combustors and incinerators are all now successfully using this process.

This dry scrubber forecast is only for the industrial sector and excludes power plants. Also no forecast is give for DSI because the scrubber is eliminated.

For more information on Scrubber/Adsorber/Biofilter World Markets, click on:

NEWS RELEASE                                                                                                    AUGUST 2014

Reverse Osmosis Equipment and Membranes Will Account For 50 Percent of the Cross-Flow Market Next Year

Sales of cross-flow membranes and equipment will exceed $10.8 billion in 2015.  Fifty percent of this total will be spent for the more efficient reverse osmosis technologies. The remainder will be split between ultra filtration and microfiltration.  This is the latest forecast in McIlvaine’s RO, UF, MF World Market.






($ Millions)




 Micro   Equipment


 Micro   Membranes


 RO   Equip


 RO   Membranes


 UF   Equipment


 UF   Membranes


Desalination applications will account for much of the market.  Reverse osmosis provides the desalting.  The other membrane technologies are often used for pre-filtration. The Middle East remains a major purchaser of desalination systems. The recent decision by Dow to locate a reverse osmosis module manufacturing plant in the region is indicative of the importance of the region.

Membrane technology growth in Asia is in part due to the need to upgrade the quality of drinking water.  The size range of reverse osmosis membrane modules has been expanding.  A 500 gallon per day module is now available. A tankless design is now possible with this large size module.

Water reuse at power plants is also driving the expansion of the cross-flow membrane market.  Many combined cycle gas turbine plants under construction and planning in the U.S. are relying on treated municipal wastewater as the water source.

Ultrafiltration and microfiltration continue to be popular in the pharmaceutical and chemical industry as a way to separate products.

For more information on RO, UF, MF World Market, click on:

NEWS RELEASE                                                                                                    AUGUST 2014

Environmental Catalyst Market to Exceed $7.9 Billion In 2015

Sales of environmental catalysts will exceed $7.9 billion in 2015.  This is the conclusion reached by the McIlvaine Company by aggregating forecasts in two separate reports which it publishes.

Catalyst   Revenues In 2015 For Environmental Applications


$   Millions

Stationary-Catalyst   For VOCs and Organic HAPS


Stationary   –NOx Catalyst


Mobile   Catalyst




Sales of mobile catalysts will far exceed those for stationary source applications.  Catalysts for VOC and organic hazardous air pollutants are utilized in catalytic oxidizers in the chemical, oil and gas, remediation and other industries.  Stationary NOx catalysts are primarily used in power plants. However, chemical plants, refineries and municipal waste combustion facilities also utilize these catalysts to reduce NOx to N2.

Both light duty and heavy duty automobiles and trucks use catalysts for organics and increasingly NOx reduction.  The large increase in vehicle use in Asia is a major factor in the relatively high growth rate for mobile catalyst sales.

A negative factor is the increasing popularity of natural gas and even LNG for vehicles. With large quantities of shale gas available in the U.S., there is an economic justification for natural gas use in trucks and other large vehicles.

The massive program to convert coal to gas in China will make gas an attractive mobile fuel.

The stationary NOx catalyst market is growing at 7 percent per year. The main driver is the decision by Chinese power plants to incorporate selective catalytic reduction on most coal-fired boilers.

Information on the VOCs and mobile catalyst is found in N007 Thermal Catalytic World Air Pollution Markets.

The information on stationary NOx catalyst is found at N035 NOx Control World Market

NEWS RELEASE                                                                                                    AUGUST 2014

Fabric Filter Market Could Be $4 Billion Larger If Catalytic Filter Is Adopted

The world fabric filter systems market will be much larger in 2017 if catalytic filter technology is adopted.  This is the conclusion of the McIlvaine Company in World Fabric Filter and Element Market.

($ Millions)     






w/o CF




With CF














The forecast without a major technology change is for 2017 fabric filter system revenues of $8.9 billion. This forecast assumes that electrostatic precipitators will remain the choice for coal-fired power plant operators.  However, a new option has become available. The catalytic filter can remove particulate, NOx and acid gases.  If operated at 850oF, it will allow for the maximum energy recovery.  If operated at 500oF, the materials of construction costs are lower and mercury can be removed. There are sorbents which can remove mercury at 500oF but not 850oF.

Power plants account for 50 percent of all the gas exhausted from the world’s industrial plants. Ninety-five of the power plants exhaust flows through electrostatic precipitators. New regulations in China, the U.S. and other countries are making it difficult to meet the new particulate standards with precipitators.  These devices do not remove NOx. They are not suited to remove acid gases and mercury even with large amounts of reagent.

One choice to meet the new regulations is to upgrade the existing precipitator, install an SCR system and install an FGD system. The cost to make these additions at a 500 MW plant is $200 million. For less than $100 million a catalytic filter system can be installed. Another benefit is more extracted heat and an efficiency improvement of 3 percent.  This results in hundreds of thousands of tons less CO2 being discharged.

  • Catalytic filters are proving to be reliable on difficult applications such as waste incineration.  The only question is lack of experience on coal-fired applications.  To further analyze this very attractive potential, McIlvaine has set up a free website on the subject:Hot Gas Filters - Continuous Analyses

A series of webinars are being conducted.  The next one is September 4, 2014.

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