EPA-450/3-78-044
February 1978
ASSESSMENT
OF MANUFACTURERS
CAPABILITY TO MEET
REQUIREMENTS FOR
PARTICULATE CONTROLS
ON UTILITY AND
INDUSTRIAL BOILERS
A
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Air and Waste Management
Office of Air Quality Planning and Standards
Research Triangle Park, North Carolina 27711
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ASSESSMENT OF MANUFACTURERS CAPABILITY
TO MEET REQUIREMENTS FOR PARTICULATE
CONTROLS ON UTILITY AND INDUSTRIAL BOILERS
Prepared by
Industrial Gas Cleaning Institute
Stamford, Connecticut 06904
Contract No. 68-02-2532
Task No. 6
Prepared for
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Air Quality Planning and Standards
Economic Analysis Branch
Research Triangle Park
North Carolina 27711
February 1978
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TABLE OF CONTENTS
Page
1.0 INTRODUCTION 1-1
2.0 MANUFACTURERS' CAPABILITIES 2-1
3.0 GUARANTEES 3-1
4.0 LIMITING ITEM ANALYSIS 4-1
11
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LIST OF TABLES
No. Page
1-1 Manufacturers Responding to the Survey and 1-2
Type of Particulate Control System Offered
by Each
2-1 Projected Number of Fabric Filters that 2-2
Manufacturers can Design and Install over
a 15-year Period
2-2 Projected Number of Electrostatic Precipita- 2-3
tors that Manufacturers can Design and Install
over a 15-year Period
3-1 Guarantees Offered by Manufacturers of Fabric 3-2
Filters
3-2 Guarantees Offered by Manufacturers of 3-3
Electrostatic Precipitators
4-1 Items Which May Delay the Design and Installa- 4-2
tion of Fabric Filters and ESP's
111
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1.0 INTRODUCTION
To comply with air pollution regulations an adequate
supply of air pollution abatement equipment must be avail-
able. The Industrial Gas Cleaning Institute (IGCI) under
contract to the U.S. Environmental Protection Agency,
conducted a survey of equipment manufacturers to determine
their ability to supply fabric filters and electrostatic
precipitators (ESP's) for use on utility and industrial
boilers.
A survey form was sent to 25 fabric filter manufac-
turers and 18 ESP manufacturers. Information was requested
from each manufacturer on the following subjects:
0 Applicability of fabric filters or ESP's to boiler
type and size range for coal-fired units.
0 Guarantees.
0 Their capability to design and install various
sizes of fabric filters and ESP's.
0 Factors which may delay the design, construction,
or start-up of fabric filters and ESP's.
0 Ways of reducing delay-related problems.
This report summarizes the results of the survey.
Table 1-1 lists the manufacturers responding to the survey
and the types of particulate control system offered. The
1-1
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I
K)
Table 1-1. MANUFACTURERS RESPONDING TO THE SURVEY AND
TYPE OF PARTICULATE CONTROL SYSTEM OFFERED BY EACH
Manufacturer
1. Air Correction Division - UOP, Inc.
2. American Air Filter Company, Inc.
3. Apitron Division - American Precision
Industries, Inc.
4. Babcock & Wilcox Company
5. Belco Pollution Control Corporation
6. Buffalo Forge Company
7. Carborundum Environmental Systems, Inc.
8. The Ceilcote Company
9. C-E Air Preheater Company
10. C-E Walther, Inc.
11. Environmental Elements Corporation
12. Envirotech-Buell Emission Control Division
13. Flakt, Inc.
14. Fuller Company
15. Industrial Clean Air, Inc.
16. Joy Manufacturing Company
Western Precipitation Division
17. Lear Siegler, Inc.
18. MikroPul Corporation
19. Peabody Air Resources Equipment Company
20. Research-Cottrell, Inc.
21. Standard Havens, Inc.
22. Wheelabrator-Frye, Inc.
23. Zurn Industries, Inc.
Type of control system offered
Fabric filter
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Electrostatic precipitator
X
X
X
X
X
X
X
X
X
X
X
X
X
X
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overall response rate from the survey was 77 percent. The
majority of the non-responding companies do not manufacture
the equipment at the present time.
1-3
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2.0 MANUFACTURERS' CAPABILITIES
This section includes a summary of the manufacturer's
capability to design and install fabric filter and ESP
systems.
Each manufacturer of fabric filters and ESP's was asked
to estimate the number of systems the company could design
and install over a 15-year period, with current and expanded
staff (or by more extensive use of subcontractors). Tables
2-1 and 2-2 summarize the information they provided. The
majority of the manufacturers said their equipment can be
used on new as well as on retrofit installations.
2-1
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Table 2-1. PROJECTED NUMBER OF FABRIC FILTERS THAT
MANUFACTURERS CAN DESIGN AND INSTALL OVER A 15-YEAR PERIOD
NJ
I
N)
Equivalent MW
5 MWed
20 MWee
50 MWee
200 MWed
1000 MWef
Equivalent MW
S MWe9
20 MWed
50 MWed
200 MWed
1000 MWef
Number of units designed ' '
1978 - 1982
With
Present
staff
1512
1249
1008
575
300
With
Expanded
staff
2237
1706
1367
749
413
1983 - 1987
With
Present
staff
1865
1550
1320
681
394
With
Expanded
staff
2402
1785
1449
810
440
1988 - 1992
With
Present
staff
1998
1636
1372
706
411
With
Expanded
staff
2590
1888
1506
824
444
Number of units installed3' 'c
1978 - 1982
With
Present
staff
1298
1014
830
454
243
With
Expanded
staff
1899
1378
1097
600
337
1983 - 1987
With
Present
staff
1562
1318
1200
660
332
With
Expanded
staff
1954
1342
1315
788
366
1988 - 1992
With
Present
staff
1618
1334
1274
656
349
With
Expanded
staff
2054
1567
1458
782
392
The number of units is based on the assumption that the total fabric filter resources of each
manufacturer is devoted to designing and installing the designated size.
Quantities shown are for systems which include flange-to-flange equipment.
The difference between the number of systems designed and the number installed is due to the
long lead time for system installation.
Represents the responses of 18 manufacturers.
Represents the responses of 19 manufacturers.
Represents the responses of 15 manufacturers.
Represents the responses of 17 manufacturers.
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N)
I
U)
Table 2-2. PROJECTED NUMBER OF ELECTROSTATIC PRECIPITATORS THAT
MANUFACTURERS CAN DESIGN AND INSTALL OVER A 15-YEAR PERIOD
Equivalent MW
5 MWe (400 SCA)d
20 MWe (400 SCA)e
50 MWe (400 SCA)f
200 MWe (400 SCA)9
1000 MWe (400 SCA)9
Number of units designeda/ 'c
1978 - 1982
With
Present
staff
1268
1097
856
572
333
With
Expanded
staff
1728
1396
1110
726
442
1983 - 1987
With
Present
staff
1340
1157
913
620
357
With
Expanded
staff
1816
1474
1194
818
499
1988 - 1992
With
Present
staff
1413
1220
971
669
394
With
Expanded
staff
1918
1558
1269
881
542
Equivalent MW
5 MWe (400 SCA)d
20 MWe (400 SCA)B
50 MWe (400 SCA) f
200 MWe (400 SCA)9
1000 MWe (400 SCA)9
Number of units installed3' /c
1978 - 1982
With
Present
staff
837
795
660
522
266
With
Expanded
staff
1196
1048
844
649
347
1983 - 1987
With
Present
staff
862
903
782
614
305
With
Expanded
staff
1237
1197
1024
799
423
1988 - 1992
With
Present
staff
933
949
845
654
355
With
Expanded
staff
1293
1232
1088
844
483
The number of units is based on the assumption that the total electrostatic precipitator
resources of each manufacturer is devoted to designing and installing the designated size.
Quantities shown are for systems which include flange-to-flange equipment.
The difference between the number of systems designed and the numbers installed is due to the
long lead time for system installation.
Represents the responses of 9 manufacturers.
Represents the response of 12 manufacturers.
Represents the response of 14 manufacturers.
Represents the responses of 13 manufacturers.
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3.0 GUARANTEES
Manufacturers were asked to indicate the types of
guarantee they offer on fabric filters and ESP's, as well as
their conditions and qualifications. Information on guar-
antees on the following specific items was requested:
0 Particulate removal efficiency (or outlet loading)
0 Predetermined installation cost
0 Performance (availability)
0 Other
Tables 3-1 and 3-2 summarize the responses.
3-1
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Table 3-1. GUARANTEES OFFERED BY MANUFACTURERS OF FABRIC FILTERS
U)
I
NJ
Company*
1
2
]
4
i
t
7
1
»
10
11
11
1]
14
li
U
17
11
1»
JO
Typ« of quarantee of foreU/condi lion*
Particulat* outlet
emission, tjr/scl
0.01b
0.015,"
0.01C
0.02-0.03b
0.02b
0.01," compliance with appli-
cable cod*
0.02b
O.Ol"
applicable coda
0.02. for specific conditions
and test MthodS
0.02b
O.OOJ6
0.02 for 12 Months at design
condition!
0.02-0.07b based on tPA test
net hod
0.01b
0.0)b
federal codesb
Non*
0.005C
0.01 or lr««
Pr«d«t«riBin*d
init«ll«tion coat
Non*
riiicd price
Hone
None
•tnd «ch*dul««
Subject to apecific condi-
tion*
conditions of »«1*
ti»* frame
Fined pr ic*»
TiMed price
None
I iont
Performanco
(Availability)
None
Y«» (conditions not
diacloaed)
None
Only on specific
None
100% when operated as
inatructed
clauses
No
Subject to specific
conditions
application
loot
condit ions
None
Subject to desiqn
condit ions
None
None
None
None
cond i t ions
Other
Filter cloth life
None
12 months on bag life
Filter cloth life,
Filter cloth life, AP
None
2 years
Standard material and
workmanship
Filter cloth life
Extended warrranties
B«9 life, power consump-
tion
Filter cloth life
None
ftP
AP, temperature
AP, bag life
None
AP, temperature, power
consumption
Opac 1 1 y
"Company
»Th,s ,u,
na*e» are deliberately withheld.
This guarantee is *|ivon on nvw units
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Table 3-2. GUARANTEES OFFERED BY MANUFACTURERS OF
ELECTROSTATIC PRECIPITATORS
u>
I
Company
Particulate
removal efficiency
Type ot ijuarantee offered/conditions
Predetermined Performance
installation cost (availability)
Up to 99.9%
Minimum 99%
90-99.5%b
95-99.9%*:
90-99.9%
99.5%b
96-99.8%, for 12 months at
design conditions
Up to 99.9%,b with a stopper
on outlet emissions
99.9%b
99.99%, with a stopper on
outlet emissions
99.5-99.9%,b with specified
conditions
98-99.5%,b with an outlet
stopper
Up to 99.8%b
Up to 99.9% with an outlet
stopperb
Up to 99.9%b
Subject to escalation clause
Subject to government escala-
tion indices
None
Firm bids provided
Yes (conditions not dis-
closed)
Subject to escalation clause
for a specified time period
For a specified time period
Subject to craft union rates
Subject to specific condi-
tions
Subject to escalation clause
Subject to escalation clause
Subject to escalation clause
Subject to specific condi-
t ions
None
None
None
Yes, based on
operating parameters
None
12 months at design
conditions
For a specified time
None
None
None
12 months
None
None
For a specified time
Other
None
AP, if required
Standard workmanship and
materials
Material and workmanship
AP, opacity
Opacity
AP, power consumption
AP, power consumption,
temperature loss
Material and workmanship
None
AP
AP, power consumption
AP, power consumption,
temperature
None
Company names are deliberately withheld.
This guarantee is given on new as well as existing units.
This guarnatee is given on new units only.
This guarantee is given on existing units only.
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4.0 LIMITING ITEM ANALYSIS
Numerous factors affect the design and installation
schedules of fabric filters and ESP's and may ultimately
affect timely completion of a project as well as its cost.
The first part of this section summarizes manufacturers'
opinions on possible bottlenecks; the latter part identifies
corrective actions to overcome delay-related problems.
4.1 FACTORS WHICH MAY DELAY THE DESIGN, CONSTRUCTION OR
START-UP OF FABRIC FILTERS AND ESP'S
Factors cited by manufacturers as contributing to delay
in design and installation of the control devices were:
0 Availability of qualified personnel
0 Component availability
0 Coordination between manufacturer, client, and
consulting engineers.
Table 4-1 shows the number of respondents within each
category.
4.2 ITEMS WHICH MAY OVERCOME DELAY-RELATED PROBLEMS
The manufacturers were asked to recommend action that
may be taken by a utility, industry, government, and others
to overcome delay-related problems. Of 14 manufacturers
responding to this question, the following item was cited by
four:
4-1
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Table 4-1. ITEMS WHICH MAY DELAY THE DESIGN, AND INSTALLATION OF
FABRIC FILTERS AND ESP's
'3
No. of manufac-
turers respond-
ing
Personnel
18
Component
11
Coordination
5
Other
0 Government regulations
0 Material shipment delay
0 Equipment delays
Represents the responses of 23 manufacturers,
both fabric filters and ESP's.
Some companies manufacture
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0 Better coordination between manufacturer and
customer
Other recommendations included:
0 Orderly planning and construction of utilities
0 Need for government definition of new emission
regulations.
0 Avoidance of artificial material shortages.
0 Equipment purchase determined by quality, not
price.
0 Avoidance of changes in design, specifications or
operation after the contract has been signed.
4-3
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TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing)
1. REPORT NO.
EPA-450/3-78-044
4. TITLE A NJD SUBTITLE
Assessment of Manufacturers Capability to Meet
Requirements for Particulate Controls on Utility and
Industrial Boilers
5. REPORT DATE
February 1978
6. PERFORMING ORGANIZATION CODE
3. RECIPIENT'S ACCESSION-NO.
7. AUTHOR(S)
V. P. Patel
8. PERFORMING ORGANIZATION REPORT NO.
9. PERFORMING ORGANIZATION NAME AND ADDRESS
Industrial Gas Cleaning Institute
700 N. Fairfax Street, Suite 304
Alexandria, Virginia 22314
10. PROGRAM ELEMENT NO.
11. CONTRACT/GRANT NO.
68-02-2532, Task 6
12. SPONSORING AGENCY NAME AND ADDRESS
13. TYPE OF REPORT AND PERIOD COVERED
U.S. Environmental Protection Agency
Office of Air Quality Planning and Standards
Research Triangle Park, North Carolina 27711
14. SPONSORING AGENCY CODE
15. SUPPLEMENTARY NOTES
16. ABSTRACT
A survey of manufacturers of particulate control equipment was conducted to determine
the industry's capability to meet the demand for control equipment required by a
change in particulate emission standards for utility and industrial boilers. The
report details the numbers and sizes of fabric filters and electrostatic precipitator:
that can be designed and installed in the 1978-1982, 1983-1987, 1988-1992 time spans.
Attention was also given to factors which might prove to be bottlenecks.
17.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.lDENTIFIERS/OPEN ENDED TERMS C. COSATI Field/Group
Air Pollution
Dust Filters
Precipitators
Air Pollution Control
Stationary Source
Boilers
13B
13. DISTRIBUTION STATEMENT
Unlimited
19. SECURITY CLASS (This Report/
Unclassified
21. NO. OF PAGES
16
20. SECURITY CLASS {Thispage)
Unclassified
22. PRICE
EPA Form 2220-1 (9-73)
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