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Clyde Bergemann NewsClean Energy Solutions Edition 01/12

Power market in South AmericaSouth America can be considered one of the most attractive emerging energy markets in the world. With more than $ 116 billion in power generation project construction starts scheduled for 2012, Latin America is one of the hottest world regions in terms of power generation project development. The top five Latin American countries for planned power generation project starts in 2012 are Brazil, Argentina, Chile, Peru and Mexico. These five countries represent 75 % of the value of planned power generation project starts in 2012.

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- Every accident is one too many – occupational safety and health are crucial when working in a power plant

- Doosan Heavy Industries & Construction selects Clyde Bergemann for Rabigh Power Plant 2 project

- Slovenia's state-of-the-art coal-fired plant decides for intelligent on-load boiler cleaning

- Case study: Process monitoring with SMART IsoTemp at coal-fired AS Pontes power plant, Spain

- Fabrication and testing of first United States DRYCONTM project completed

- Clyde Bergemann Power Group Americas awarded a contract from Metso for the GREC Fabric Filter & Injection Systems

- DeNOx performance exceeds expectations of Chinese 1,000 MW power plant

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- Clyde Bergemann Power Group Americas awarded over US$ 20 million in contracts for gas-fired power plant equipment

- Power surge in the Middle East- Clyde Bergemann Termotec expands

resources- Imtech Deutschland chooses Clyde

Bergemann technology - Partner of steel and copper industry- High Energy Efficiency Burner for

emissions far below the legal requirements- Technology Seminar supporting UK Waste

to Energy & Biomass markets- Annual Clyde Bergemann Power Group

Sales Conference- Doncaster enterprise for learning- Events Diary- Personnel Developments

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- Power market in South America- Indonesia – sustained growth for power

sector- SMART CleanTM solutions to latest EPA

regulations- Challenges and opportunities by use of

biomass in coal-fired power plants- New on-load boiler cleaning system for

boilers fired with waste, biomass and refuse-derived fuels

- First biomass unit to implement complete SMART CleanTM system

- Clyde Bergemann Atlanta secures first Shower Cleaning System order

- On-load boiler cleaning systems at a glance

- Clyde Bergemann Africa team plays it safe at Medupi Power Station

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www.clydebergemannpowergroup.com

Latin American economies are charging, despite of global economic woes, growth rates of 7 percent or even higher in some countries. Energy needs are expected to grow in tandem or even faster. For instance, power demand grew 11.5 percent in Brazil in 2010, and an average 4.5 percent per year since 2001 in the region as a whole. Brazil and Mexico, among other Latin American economies, are in dire need of new electricity generation to fuel their growing economies.

The need to curtail increasing carbon emissions resulting from strong economic growth is imperative to Latin American countries, if they are to remain competitive and to maintain a sustainable energy growth. Demand for goods is becoming ever more sensitive to the carbon footprint they carry, especially in developed countries. The IEA’s Current Policies Scenario from their yearly World Energy Outlook publication states that Latin America could increase its CO² emissions by roughly 50 percent between 2008 and 2035. Latin America is still developing more coherent policies and regulatory frameworks for all renewable energy sources, as commitment to renewables in general grows. It is expected that current challenges will be ironed out in time, allowing clean energy investments to increase even more in the region. This will secure a clean and competitive future

energy supply that will support economic growth, also positioning the region’s countries well, as the cost of fuels and emissions increases in the future. Chile currently has 12 coal-fired power projects under development. The projects have a total investment value of $ 7 billion, four of which are in the engineering phase, five in the planning phase, and the remainder under construction. Some of the largest plants include the 740-MW Punta Alcalde coal-fired power station, the 152-MW

Guacolda coal-fired unit addition, and the 750-MW Mejillones coal-fired unit addition. President Piñera stated that by 2020 an additional 8,000 MW will need to be added to the national grid in order to respond to the country's future demand for electricity.Argentina is second in Latin America for the value of power project starts for 2012, with 61 projects totaling $ 13.8 billion. Argentina relies mainly on thermal generation (61 % of installed capacity) and hydropower generation (38 %). New renewable energy technologies are taking off in the country. The Patagonia region has some of the best conditions in the world for wind power generation.

Brazil, with 294 projects totaling $ 43.4 billion, leads the region, accounting for about 37 % of the value of projects scheduled to begin construction during

the year. These projects will add 31 GW to the current 117.5 GW online in Brazil. During the same period of time, about 48 new power plants accounting for 7.51 GW will begin operations, representing a 6 % increase in the country's total installed capacity. This growth is boosting output to 145 GW in readiness for Brazil to play host to the 2014 World Cup and the 2016 Olympic Games. Brazil's explosive economic growth is expected to cool slightly before the 2014 FIFA World Cup. However, that year, the South American nation's economy will eclipse that of India to become the world's sixth largest, according to the Economist Intelligence Unit. And by 2020, Brazil could also outflank Germany, becoming the world's fifth biggest economy.

These figures point to Brazil's heavy reliance on renewables. This trait has been emphasized over the past years, after the government decided to organize periodic energy auctions as a means to foster power generation, transmission and distribution by helping power producers make their way into the consumer market. The system has helped lower the price that users pay for electricity. The auctions have promoted renewable energy sources above others. To help increase energy from alternative sources and make the required technology more easily available, the government has also sponsored auctions specifically oriented for a specific renewable source, such as wind power or biomass-fired power.

Chile, Peru, Mexico, Panama, Ecuador, Bolivia, Venezuela, El Salvador, Uruguay, Costa Rica and Colombia all have in excess of $ 1 billion worth of scheduled Power Industry project starts in 2012.

Power market in South America

Franz BartelsClyde Bergemann Power Group

[email protected]

Contact Details:

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Sources: Industrial Info Resources, Power Engineering International, World Energy Insight 2011

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Indonesia – sustained growth for power sector

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2010 2011 2013 2015 2017 2019

Indonesia

Java-Bali

Western Indonesia

Eastern Indonesia

TWh

Agustinus TjhayClyde Bergemann [email protected]

Contact Details:

Power plant type Capacity (MW)

Coal power generation 7,616

Combine cycle 1,440

Hydro 174

Geothermal 2,125

Source: RUKL PLN 2010-2019

Source: RUPTL PLN 2010-2019

John CannonClyde Bergemann [email protected]

Forecast electricity demand (in TWh) in Indonesia

Indonesia is a large archipelago with over 17,000 islands and a population of around 234 million, the fourth most populous country in the world. Population, economic activity and industry are most concentrated in Java and Sumatra Islands. As of 2011, Indonesia’s GDP growth stands at around 6.1 % and nominal GDP is US$ 700 billion. Indonesia has no interconnection system to the smaller remote islands, the main islands for transmission electricity are Java-Bali, Sumatra, Kalimantan and Sulawesi.

Until the first quarter of 2011 the electrification ratio in Indonesia stood at 68 %, some 12 % behind the state electricity company PLN and Energy and Mineral Resources ministry target of 80 % electrification by 2011. Indonesian electricity demand growth annually is forecast at 9.5 %, and annually additional power generation is 7.8 GW with composition coal power plant 58.8 %, combine cycle 12.6 % and the rest 28.6 % is renewable energy.

To meet this demand, the Indonesian government has implemented a 10,000 MW acceleration program, phase 1 and phase 2. The construction of the phase 1 acceleration program has been completed and 80 % of the plants are now operational.

The power generation fleet on phase 2 acceleration program is on the table below.

Phase 2 acceleration program’s focus is to fulfill electricity demand on the smaller islands and remote areas which cannot be reached by the interconnection system.

In order to tackle this situation,the Indonesian government will build small sized power plants with a capacity below 100 MW in the remote areas. In total, around 120 units or 75 % of the total power generation will be built up this way.

In light of these market developments and future potential in Indonesia, the Clyde Bergemann Power Group has opened a business unit in the city of Jakarta. The locality of the new facility along with local knowledge of the team put in place to run the establishment will ensure that the Clyde Bergemann Power Group is in a key position to support this market. PT. Clyde Bergemann Indonesia, as it is now known, covers the business territory for Indonesia, Malaysia, Singapore, the Philippines and Vietnam.

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Challenges and opportunities by use of biomass in coal-fired power plantsLode Smeets, Project Manager Renewable Energy at Tractebel Engineering, summarizes the key aspects of the use of biomass in coal-fired power plants.

Tractebel Engineering offers international, independent and multidisciplinary expertise for direct biomass combustion, co-combustion, bio-gasification and bio-methanation installations, from early identification of a potential project to commissioning. Through 15 years of experience in biomass projects, generating a total of more than 600 MW, Tractebel Engineering has developed a technology for biomass handling and co-firing in large scale power plants.

Availability & qualityBecause of their relatively high energy density, availability and combustion characteristics, clean industrial wood pellets are considered to be the preferred fuel for

the conversion of large scale coal plants. Clean wood pellets are mainly drawn from forest residues from the sawmill industry. The demand for pellet is expected to rise rapidly, from 15 million t/y to up to 50 million t/y by 2020. Nevertheless, the pellet market remains immature compared to coal with a consumption of 7,000 million t/y. International quality standards are still non-existing while the quality is decreasing due to the growing demand. These issues have to be taken into account from the beginning when considering biomass firing on a large scale.

Biomass co-firingIn general, a plant for biomass co-firing consists of train or ship unloading facilities,

a pre-cleaning step, pellet storage units, pellets milling into dust and a pneumatic wood dust transport system to the burners.Biomass is more difficult to grind compared to coal and needs a adequate milling system. After milling, wood particles still remain larger than coal – up to 1.5 mm vs. 0.075 mm. This slows the heat up and volatiles release, causing delay in ignition and the need for longer residence time for complete burnout. Higher co-firing rates will impact the boiler behavior. Modifications to the combustion air system, burners and flue gas cleaning system have to be evaluated for each case separately. Depending on the quality of the pellets and performance of the milling system, increased unburned carbon, slagging, fouling and corrosion rates also

SMART Clean™ solutions to latest EPA regulations

In light of the latest Environmental Protection Agency’s (EPA’s) regulations, it is important for plants to understand what is needed remain compliant and what kind of economic impacts they can expect. Clyde Bergemann Atlanta’s SMART Clean™ technologies, in combination with products from our sister companies, offer a total cost efficient solution for plants who are looking to lower emissions and retain their efficiency.

The “Utility MACT” rule, set by the EPA, requires coal and oil-fired power plants to reduce emissions of CO², SO², mercury and other toxics within the next three years. The emission limits must represent Maximum Achievable Control Technology (MACT), defined as the top 12 % performance of existing units.

In order to meet these emission limits plants will need to install air pollution controls, including activated carbon injection (ACI), scrubbers or dry sorbent injection (DSI), and upgrade particulate control systems such as fabric filters and electrostatic precipitators (ESP). These technologies, however result in parasitic power loss. Parasitic power loss is referred to as the reduction in efficiency or MW output new equipment consumes from the plant, with no added benefit. SMART Clean™ can help plants regain this lost efficiency, resulting in a quicker return on their investment.

Studies done by the EPA, National Energy Technology Laboratory (NETL), and Sargent and Lundy all show Intelligent Sootblowing as one of the recommended technologies plants can use to increase boiler efficiency,

thereby reducing emissions. The studies also show the economic benefits of Intelligent Sootblowing as being the most cost effective method.

Tim MartinClyde Bergemann Atlanta, USA

[email protected]

Contact Details:

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require specific attention and mitigating measures. The extent depends on the boiler design but a 100 % conversion to biomass causes a derating in almost all cases.

RisksThe handling of pellets always generates dust due to pellet decomposition. Because wood dust is very explosive, every biomass installation has to be designed according to a safety first approach. Through years of experience, Tractebel Engineering has defined the necessary measures for fire and explosion protection, first to prevent the formation of an explosive atmosphere: dedusting systems, closed conveying, etc.; prevention of ignition sources; detection systems for early warnings; and finally to limit the impact of an explosion: explosion panels, compartmentation, suppression systems, etc.

DevelopmentsTractebel Engineering evaluated combustion technologies and solutions for highest global electrical net efficiency with biomass. The study demonstrated electrical net efficiencies of more than 42 % to 44 % are now feasible. When considering a biomass project, rather than the investment costs it is important to look at the total cost of ownership for a biomass plant. Fuel costs in general represent about 70 % of the total costs while CAPEX & OPEX take only approximately 15 % each for their account. The increasing demand for biomass fuels makes the profitability of a project largely dependent on the ability to burn more challenging fuels.

Lessons learned:• SAFETY – “Safety first approach”

The question is not how to avoid explosion because it will explode, but how to manage the explosion.

• COMBUSTION – “There is no such thing

as clean biomass” Slagging, fouling, corrosion provoke less

efficiency and less availability.• ECONOMICS

Fuel cost represents 70 % of the total costs, the focus has to be on fuel flexibility.

• SOURCING

Market not yet mature, no real fuel quality standards defined. The supply chain needs to be secured.

Some references of Tractebel Engineering:Gelderland power plant (The Netherlands): 600 MW – CFPP converted to 25 % pellet co-firing | Rodenhuize power plant (Belgium): 285 MW – CFPP converted to 100 % pellet co-firing with a capacity of 195 MW | Polaniec power plant (Poland): 195 MW – greenfield circulating fluidised bed unit (20 % agri / 80 % wood chips)

Lode SmeetsTractebel [email protected]

Contact Details:

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New on-load boiler cleaning system for boilers fired with waste, biomass and refuse-derived fuels

Fuels with the most variable heating values and chemical compositions are used in incinerators and biomass boilers. Due to their tendency to develop complex deposits, waste, refuse-derived fuels and biomass are seen as challenging energy sources.

Incinerators and biomass boilers often have low steam parameters for the sootblowers so intensive cleaning is not possible. The strong deposit build-up in the convective area can also mean that conventional steam sootblowers will not work effectively. Consequently, the fouling will continue to increase, causing unplanned downtimes and reduced boiler availability.

The new RX-SMART Helix-W is a fully automatic cleaning system using water as the cleaning medium. It consists of along retractable sootblower and a mediasupply unit with modules for the pump, for water inlet, water outlet and an automation unit.

RX-SMART Helix-W employs two gear motors, one for the axial and one for

the rotational movements. This enables the cleaning system to precisely position the water jet in the gaps between the heat exchanger tubes and to perform the cleaning rotating without axial speed. This so-called “Go-Stop-Clean-Go” mode avoids metal surfaces being hit by water and therefore thermal load. Sophisticated control of the water circuit ensures that the water jet will only be applied for cleaning and interrupted on the spot by a pressure-active nozzle. If no cleaning is performed, the nozzle stays closed so that the water cools the long retractable sootblower in a closed cooling circuit.

Water as the cleaning medium is capable of producing the required intensive cleaning effect. To perform the cleaning as gently as possible on the heat exchanger pipes, specially designed hardware and software components and two gear motors with incremental rotary encoders ensure that the RX-SMART Helix-W moves precisely to the cleaning position within the space between the heat exchanger tubes. Water is released for cleaning only.

Novel water jet controls guarantee an instant build-up and interruption of the water outlet from the pressure-active nozzle. If no cleaning is performed, the entire water flow is used for cooling the long retractable sootblower in a closed cooling circuit.

The operation of this new on-load boiler cleaning system can be viewed by means of a 3D animation at www.clydebergemann.de under the section Media/Downloads. A brochure is available there, too.

RX-SMART Helix-W

Arnd BenninghoffClyde Bergemann GmbH, Germany

[email protected]

Contact Details:

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Clyde Bergemann Atlanta secured its first Shower Cleaning System (SCS) order with Covanta Energy’s Niagara Plant located in Niagara Falls, New York. This energy-from-waste plant processes 2,250 tons of waste per day selling the steam to adjacent chemical facilities and the electricity to the New York State power grid.

The use of waste and biomass as a fuel is a challenge. Noticeable consequences of this are increased deposit formation in the open passes, accelerated corrosion processes, and unplanned shutdowns. In particular, deposits in the open passes of incinerators strongly influence plant availability. Fouling on the membrane walls of the open passes can lead to significantly reduced heat transfer which consequently increases superheaters. Raised flue gas temperature the

flue gas temperature before the and corrosive chemical components combine to produce a substantial risk for high-temperature corrosion.

When using waste and biomass as the fuel, the cleaning effectiveness of a water based on-load boiler cleaning system depends on the actual fuel composition and the consequential deposit characteristics. Clyde Bergemann’s SCS uses water as the cleaning medium. Located on the boiler roof, it removes deposit from the lower side, the membrane walls, the pendant heater, and superheater surfaces. By using different nozzle designs and cleaning parameters, the cleaning efficiency can be adjusted to specific surface deposit characteristic.

Advantages of using SCS on waste and biomass fired boilers include:

• Increased plant availability due to reliable cleaning of the open passes which are important for efficient plant operation

• Stable flue gas temperature• Lower risk for high-temperature corrosion

and reduced corrosion rate• Shorter revision period as time-

consuming manual primary cleaning is almost eliminated

• The construction of SCS allows cleaning of narrow designed open passes

• Corrosion protection of the flange by applying sealing air

First biomass unit to implement complete SMART Clean™ system

Clyde Bergemann Atlanta is working with Factory Sales & Engineering, Inc on a project for the Abengoa Cellulosic Ethanol Plant in Hugoton, Kansas. The facility, scheduled to be commissioned in 2013, will convert about 315,000 dry tons per year of crop residue and cellulosic energy crops to 25 million gallons of ethanol, while also generating 25 megawatt (MW) of electrical power.

This project is the first biomass unit to implement Clyde Bergemann’s complete SMART Clean™ system and will include: US Retractable Sootblowers, Cleaning

WLB100A SMART Cannon System, 9 SMART PLC Module, 15 US Partial Retractable Sootblowers, SMART Convection, and SMART Controls.

Abener Engineering (a division of Abengoa) was tasked to design and engineer the new biomass unit which will burn a variety of challenging fuel including corn stover, wood chips, switchgrass, syrup from ethanol manufacturing process, waste treatment sludge, etc. This will be the first biomass unit in the world to burn these types of fuels which have a very low ash fusion temperature and a high slagging tendency. Severe slagging is expected from the furnace to the backpass portion of the boiler. In addition, this unit will supply steam and power to the ethanol

manufacturing process making reliability critical.

Our SMART Clean™ technologies proved the best fit for this challenging application. The SMART Cannon can remove the molten slagging in the furnace very effectively while our SMART US Sootblowers can target the specific slagging area in the superheater and generating bank to prevent them from plugging. The use of SMART Convection will tell which tube bundle is dirty and remove the slag before it gets too severe to clean. For the low temperature areas such as economizer and air heater, partial tract retractable sootblowers are very cost effective and clean more effectively than rotary sootblowers, which were the standard design for small biomass units.

Clyde Bergemann Atlanta secures first Shower Cleaning System order

Shower Cleaning System

Huiying ZhuangClyde Bergemann PG Americas, [email protected]

Contact Details:

John MaloneClyde Bergemann PG Americas, [email protected]

Contact Details:

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On-load boiler cleaning systems at a glance

In a new brochure, Clyde Bergemann presents the complete scope of supply for the efficient cleaning of heating and reaction surfaces. This 20-page brochure covers all devices which remove slagging and fouling by means of steam/air, water or by impact energy. Solutions for boiler diagnostics/analysis and optimization as well as the in-house competence in automation are covered, too.

This brochure is available at www.clydebergemann.de under the section Media/Downloads.

Clyde Bergemann Africa team plays it safe at Medupi Power Station

On 12 October 2011, the Clyde Bergemann Africa (CBZ) team on Package 32, Medupi Power Station, reached their safety target of 150,000 hours LTI (Lost Time Injury) free. This is the second Health & Safety achievement for the year 2011, after the team was awarded a gold certificate for one year without LTI in August.

CBZ was rated by the Medupi Engineering Team as the best contractor for its size in terms of quality, with a nearly perfect

record over five audits. CBZ’s scope for Medupi is the design, construction, supply and commissioning of the fly ash handling and conditioning systems. The company is also acting as the on-site construction supervisor taking care of erection control and commissioning services for the on-load boiler cleaning equipment supplied by Clyde Bergemann in Germany.

The team’s goal is to still be LTI free in April this year when the next 6-monthly

assessment is done. Responsible for this impeccable record are Gerardine Henning (Safety & Environmental Officer) and Eliza Haystek (Quality Officer).

Jaco van der WesthuizenClyde Bergemann Africa, South Africa

[email protected]

Contact Details:

View of Medupi power station, Lephalale, in South Africa

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Every accident is one too many – occupational safety and health are crucial when working in a power plant

Erich StratmannClyde Bergemann GmbH, [email protected]

Contact Details:

Employees of Clyde Bergemann GmbH in Wesel, Germany show competence of high safety standards by passing SCC checks successfully.

Occupational safety is of major importance to power plant operators. Suppliers can be excluded from contract qualification if they show no evidence of compliance with safety standards. Certification under “Safety Certificate Contractors“ (SCC) assesses the health and safety management system of companies performing work on the premises of third parties.

Since 2005, Clyde Bergemann GmbH has been certified in accordance with SCC guidelines that apply all over Europe. The SCC certificate provides evidence to Clyde Bergemann’s customers – among which are operators of coal-fired power plants, incinerators and industrial boilers – that employees have received training in all aspects of occupational safety and health protection.

In order to qualify for the certification process or to retain the seal of approval, no more than two reportable industrial accidents should have occurred during any given year. Quite recently, another 35 employees of Clyde Bergemann came together to attend a preparatory workshop with subsequent examinations in the in-house training and conference center in Wesel, Germany. Topics ranged from legal aspects to the identification and assessment of risks and analysis of accidents. The Elsevier Academy, as an accredited SCC auditor, supervised and evaluated the examination results. All participants have successfully provided evidence of their proficiency.

Employees of Clyde Bergemann GmbH in Wesel, Germany attend a preparatory workshop for SCC examination at the in-house training and conference center.

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Doosan Heavy Industries & Construction selects Clyde Bergemann for Rabigh Power Plant 2 project

The on-load boiler cleaning devices for the new build Rabigh Power Plant 2 will be supplied by German-based Clyde Bergemann GmbH. South Korea’s Doosan Heavy Industries & Construction recently ordered 160 long retractable sootblowers type PS-LL along with Thermo Probes. The control system will also be commissioned by Clyde Bergemann.

The 4 x 700 MW heavy fuel oil and crude oil fired units are located 150 km northwest of

Jeddah, Saudi Arabia. The end user is Saudi Electricity Company.

Compared to the figures in 2000, the country’s electric power consumption is expected to triple to 309,100 GWh by 2016.

Slovenia’s state-of-the-art coal-fired plant decides for intelligent on-load boiler cleaning

EPC-contractor ALSTOM Power Systems GmbH, of Stuttgart, Germany, awarded a contract to Clyde Bergemann as the sole supplier of the on-load boiler cleaning solution for unit 6 of the Šoštanj coal-fired power plant in Slovenia. With a net efficiency of 43 %, the new 1 x 600 MW ultra supercritical tower-type unit, whose construction is in progress, will make this station one of the most efficient and advanced in Slovenia.

According to the specific cleaning requirements of the different boiler areas, e.g. furnace, superheater, economiser,

air heater and DeNOx, the overall 128 sootblowers consist of the series water cannon, long retractable, helical, rake and rotating element. The furnace will be equipped additionally with the SMART Furnace-FACOS optimisation system. This system uses sensors to detect the position and intensity of slagging in the furnace area. This data will be linked with the current performance data of the steam generator to decide upon stored algorithms which cleaning action needs to be done and at what intensity. SMART Furnace-FACOS not only regards the level of slagging but also the influence of the imminent

cleaning operation on boiler performance. Clyde Bergemann carries out engineering, installation and commissioning.

Termoelektrarna Šoštanj d.o.o. operates the Šoštanj station. Coal is supplied by the nearby Premogovnik Velenje lignite mine. When operational in 2014, unit 6 replaces the older units which have been brought on line from 1956 to 1977.

Power Plant Šoštanj

Arnd BenninghoffClyde Bergemann GmbH, Germany

[email protected]

Contact Details:

Ulrich BalsmannClyde Bergemann GmbH, Germany

[email protected]

Contact Details:

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Case study: Process monitoring with SMART IsoTemp at coal-fired As Pontes power plant, Spain

SituationVariable boiler operation with changes in mill and burner combination leads to unpredictable imbalance in the flame position. This results in thermal overload at the membrane walls in the evaporator. Slagging hotspots will build on these areas of the furnace.

By altering the boiler design and changing from local lignite coal to imported sub-bituminous coal the problems cannot be completely avoided. In thermal overloaded areas, the evaporator tends to slag, in spite of using imported coal with a very low ash portion.

Objective targetThe main objective target of using SMART IsoTemp was to gain a stable operating performance by retention of the variable boiler operation. Essential for this was to have a symmetrical and constant positioning of the flame in the middle, which would

promote the cooling of the ash particles in the vicinity of the wall.

This results furthermore in a reduction of deposit formation. Thereby, the formation of local limited slagging in the furnace can be reduced.

SolutionImportant control parameters for qualitative evaluation of the combustion are the flame and flue gas temperatures.

SMART IsoTemp is an optical measurement device which records and evaluates these parameters continuously and contactless in real-time. Based on the results, corrective actions in the firing operation can be carried out just in time to keep the temperature in optimised operation and to stabilize the operation performance.

RealizationThe furnace conditions call for six SMART IsoTemp pyrometers. To establish the desired optimisation all SMART IsoTemps have to be installed at the same level at the boiler wall at the end of the furnace. Due to the high ambient temperatures, a fibre optic detects the radiative temperature of the furnace and sends this to the pyrometer.

A PC-based detection system transfers the radiation into temperature signals, from which the temperature profile of the complete furnace section will be generated. The visualization is presented in a two dimensional image. Using an interface, the visualization along with the measured temperature signals, the temperature distribution and the absorption coefficients will be transferred to the process control system.

The control centre receives easily interpretable information and is able to optimize the following parameters in real-time:• Air feed and velocity• Fuel mass flow• Burner and mills combinations

Results:• Transparent process flow – The control

centre easily recognizes the quality of the combustion process and can optimise it in real-time. This is especially helpful during the start-up process of the boiler after shut-downs, strong reductions in the boiler load and changes in mills.

• Results of the corrective actions for flame adjustment will be recognized.

• Changes in the fuel mix are procedural and at any time controllable. The important control parameters, flame temperature and location, are continuously monitored so that the temperature distribution can be presented as information that is easily understood.

• High fractions of unburned coal can be noticed.

Daniel BartelsClyde Bergemann GmbH, [email protected]

Contact Details:

Visualisation of the temperature distribution by thermal diagnosis with SMART IsoTemp

Installed SMART IsoTemp for thermal diagnostics

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Clyde Bergemann Power Group Americas (CBAM) has successfully managed to fabricate, assemble, and test their first DRYCON™ module for Seminole Electric ahead of schedule and under budget. Seminole Electric’s two 650 MW coal-fired units in Palatka, Florida needed to convert their existing wet bottom ash

removal system to a dry system. CBAM was awarded the contract to supply engineering and equipment utilizing our DRYCON™ technology.

With the project being awarded last March of 2011, Clyde Bergemann Malvern used CBAM's engineering team in Atlanta and CBAT's facility for fabrication with a completion date goal of spring 2012. As of the beginning of February 2012, the secondary conveyor for the DRYCON™ project has been completed, tested, and shipped. Fabrication for the primary conveyor has been completed with assembly underway. Testing of the unit will occur mid February with shipment happening at the end of the month. The whole CBAM team has worked very closely

with Seminole Electric to ensure timely delivery of the project and to meet their budgetary expectations.

Ron Tempesta, President of Clyde Bergemann Malvern, comments: “This is the first DRYCON™ project fabricated in North America for Clyde Bergemann and we are very pleased with the results we have achieved. This demonstrates CBAM's ability to deliver on-time, on-budget results. We hope this will open the door for future opportunities at other major North American utilities with Clyde Bergemann Malvern's DRYCON™ technology and other potentially new product lines."

Fabrication and testing of first United States DRYCON™ project completed

Clyde Bergemann Power Group Americas awarded a contract from Metso for the GREC Fabric Filter & Injection Systems

Clyde Bergemann Power Group Americas (CBAM) headquartered in Atlanta, GA has been awarded a contract from Metso Power to provide the multi-pollutant emissions control system for the Gainesville Regional Energy Center (GREC) BFB Biomass plant in Gainesville, FL. The system is being supplied by Clyde Bergemann Hanover, the air pollution control business unit within CBAM. The GREC plant, which will burn waste wood from logging and mill activity as well as urban wood waste from clearing, is scheduled to come online in 2013.

Due to the strong positive relationship between the two companies, Metso is very confident in Clyde Bergemann’s ability to apply its proprietary technology to achieve the low air emissions required for the GREC project. Clyde Bergemann’s APC solution

includes its proprietary pulse jet fabric filter, dry sorbent injection and activated carbon injection systems to achieve the cleanest air emissions ever required for a biomass boiler in the USA. The modular fabric filter will utilize proprietary technology and be applied to the hot side of the plant‘s low dust SCR, handling elevated gas temperatures while achieving filterable particulate matter emissions consistent with the plant’s air permit.

In coordination with the fabric filter, an activated carbon injection system will provide dioxin/furan and heavy metal control while a sodium-based injection system provides acid gas mitigation. The material handling equipment for the injection systems will be furnished by Clyde Bergemann Malvern, CBAM’s Material

Handling business unit. The complete fabric filter and sorbent injection systems will be delivered to site in early 2012.

Mike NewburyClyde Bergemann PG Americas, USA

[email protected]

Contact Details:

Clyde Bergemann’s fabric filter and APC solutions

DRYCON™ for Seminole Electric

Ron TempestaClyde Bergemann Malvern, USA

[email protected]

Contact Details:

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DeNOx performance exceeds expectations of Chinese 1,000 MW power plant

In October 2007, Clyde Bergemann Huatong signed a contract to supply advanced DeNOx technique for 1,000 MW unit 5 of the Anhui Energy Tongling Power Plant Phase VI. The scope of supply covered conceptual design, detail design, equipment procurement and delivery, erection supervision and commissioning on-site. Major equipment of the system are DeNOx reactor, duct work, catalyst, dilution fan, sonic blower, ammonia tank, evaporator, flow regulator, pressure regulator station as well the required instruments and electrical equipment. This is the first DeNOx system supplied by Clyde Bergemann Huatong.

In May 2011, the 168-hour trail-run of unit 5 came to end and CBH’s first DeNOx system was successfully put into operation. During the trail-run operation, as the first ammonia injection succeeded, the DeNOx system was put in automatic run and it is shown that DeNOx efficiency was satisfactory to the specification.

In September 2011, the DeNOx system’s performance 5 day tests, attended jointly by Anhui Energy Tongling Power Plant Co., Ltd, general contractor of Tongling Power Plant, Clyde Bergemann Huatong and Xi’an Thermal Power Research Institute Co., Ltd, was going smoothly. The performance tests include all parameter measurements at two full load at 1,000 MW, one medium load at 700 MW and one low load at 500 MW conditions. The measured parameters are DeNOx efficiency, SO² / SO³ conversion rate, ammonia slip rate, ammonia consumption and pressure loss of the DeNOx system as specified in the contract.

The results indicate that all the actual performance values are better than the specified ones. The success of Clyde Bergemann Huatong’s first DeNOx system has laid the foundation for future projects.

Xiao WeinongClyde Bergemann Huatong, [email protected]

Contact Details:

Parameter Unit of measurement

Performance guarantee value Actual test value Conclusion

De-NOx efficiency % 75 76.5 (full load) conforming

75 76.1 (medium load) conforming

75 77.3 (low load) conforming

Ammonia slip µL/L 3.0 0.56 (full load) conforming

3.0 0.44 (medium load) conforming

3.0 0.27 (low load) conforming

SO²/SO³ conversion rate % 1.0 0.19 (full load) conforming

Pressure loss Pa 800 636 (full load) conforming

Ammonia consumption kg/h 440.7 210.6 (full load) conforming

With collaboration, Clyde Bergemann Huatong and Xi’an Thermal Power Research Institute Co., Ltd carried out these tests, and the results were recorded as follows:

14


Clyde Bergemann Power Group Americas awarded over US$ 20 million in contracts for gas-fired power plant equipment

Clyde Bergemann Auburn, the air-gas handling division of Clyde Bergemann Power Group Americas, has secured contracts totalling over US$ 20 million to supply equipment and services for new power plants being constructed in Africa and the Middle East.

The company was selected to supply dampers, stacks, silencers and other exhaust system components and services for gas-fired plants in Egypt and the United Arab Emirates. These projects will add nearly 4,000 MW power generating capacity in a region that is experiencing tremendous growth in energy demand. The plants are expected to begin operation by the middle of 2013.

“As evidenced by these awards, Clyde Bergemann Auburn‘s reputation for delivering quality technology is recognized globally, and we continue to demonstrate our strengths in a very competitive environment“, said President Fred Koch.

The equipment will be installed in gas-fired combined cycle power plants designed for high efficiency and low carbon emissions. A combined cycle plant, which conducts secondary processing of combustion exhaust by way of a heat recovery steam generator, typically produces approximately 50 % more energy thus causing less carbon dioxide and other pollutants than a conventional simple cycle plant generating the same MW.

Clyde Bergemann Auburn’s customers, engineering, procurement and construction (EPC) companies for the projects are based in China and Korea. The company has previously collaborated with the firms on numerous projects around the world.

Commenting on the market outlook, Koch said, “We are now seeing some good activity in our core markets. These orders reflect a strong company-wide effort and intense focus on our markets, customers and opportunities.”

Clyde Bergemann Auburn, is a global engineering company focusing on high-performance clean energy solutions for Power, Utility, Petrochemical, and Industrial applications. The company develops and supplies custom designed and fabricated systems including dampers, diverters, expansion joints, stacks and exhaust system components for gas turbine and fossil fired power plants. The company is ISO 9001:2008 certified.

Chris CaiazzoClyde Bergemann Auburn, USA

[email protected]

Contact Details:

Guillotine damper as part of a combined cycle gas turbine system

Combined cycle gas turbine system

15


Power surge in the Middle East

Quickly becoming one of the most exciting markets for power generation development is the Gulf Cooperative Council (GCC) region of the Middle East. Energy demand in the GCC, which encompasses Bahrain, Kuwait, Oman, Qatar, Saudi Arabia, and United Arab Emirates, is experiencing aggressive growth.

Driven by accelerated economic development, a growing population, and water desalination initiatives, the corresponding increase in energy demand – currently about 8 % annually – is fueling a robust rate of construction of power generation facilities throughout the region.

Most of the electricity generation capacity coming online in the Middle East is from gas- and oil-fired plants, in some cases very large-scale “mega” installations constructed in multiple phases involving 10-, 20-, or more, unit configurations.

Many electricity producers seeking to boost output rapidly at existing facilities are repowering their existing simple cycle plants to more efficient and cleaner combined cycle operation. Repowering of a simple cycle gas turbine unit consists of adding a Heat Recovery Steam Generator (HRSG) so that the exhaust gas which was being ejected to the atmosphere is now sent through the HRSG to provide steam for either electric generation by a separate steam turbine or for some other process (e.g. desalination, heating, etc.).

A combined cycle plant typically produces approximately 50 % more energy than a simple cycle plant with the same amount of fuel. Combined cycle plants also cause less carbon dioxide and other pollutants than a conventional simple cycle plant generating the same MW.

Clyde Bergemann Auburn (CBAU), a business unit of CBPG, is participating in one of the largest energy projects in Saudi Arabia. The company is participating in the repowering of the existing PP10 site in Riyadh. The project will increase the plant’s capacity from 2,200 MW to 3,400 GW. CBAU supplied the original simple

cycle stacks which were required to be capable of future conversion to combined cycle operation The CBAU repowering scope of supply includes converting the previously supplied elbows to diverter dampers, blanking guillotines, and auxiliary equipment.

Industry experts foresee energy demand continuing to grow steadily over the long term, in fact, tripling over the next 25 years. The World Energy Council estimates 100 GW of additional capacity, representing investments of US$ 50 billion in power generation and US$ 20 billion in desalination, will be required in just the next decade.

Such sustained growth will call for long-term additions to the Middle East’s power grid, supported by reliable equipment that is up to the task of operating reliably and economically under extremely challenging ambient conditions. Clyde Bergemann

Auburn’s proven track record in the region will continue to make it the supplier of choice for major power projects requiring high performance air-gas handling equipment.

Robust growth prompting new construction projects

Chris CaiazzoClyde Bergemann Auburn, [email protected]

Contact Details:

16


Clyde Bergemann Termotec expands resources

Since 1982, Clyde Bergemann Termotec has been a competent partner for heat exchanger plants. Within the Clyde Bergemann Power Group, Clyde Bergemann Termotec is one of the centers of competence in the field of energy recovery. From development and design to production and true-to-size installation, Clyde Bergemann Termotec provides forward-looking and customized solutions.

Recently, the team covering the range of dry cooling heat exchangers and air-cooled condensers has been enforced by a group of well experienced specialists in dry cooling technology. Richard Leitz, Kurt Rüdel and Hans-Georg Schrey joined the company and implemented their long-term experience, especially with regard to air-cooled condenser design and optimization.

Richard Leitz is the Director Air Cooled Condenser, Kurt Rüdel acts as Sales Director

Air Cooled Condenser and Hans Georg Schrey is responsible for the design and development of Air Coolers.

The demand for air-cooled condensation has been constantly growing over the past decade on a world-wide scale. Thermal power, solar, biomass stations as well as pulp and paper plants are key users of dry condensation technology.

Air-cooled condensers are environmentally friendly because no cooling water is required and no waste generated. Clyde Bergemann Termotec supplies air-cooled condensers in classical A-Frame or vertical arrangement with multi-row or single-row technology. Starting from the turbine exhaust the complete cold end of the steam cycle is designed and engineered by Clyde Bergemann Termotec engineers.

The Clyde Bergemann Termotec Dry Cooling team (left to right):Ralph Ludwig (Managing Director), Kurt Rüdel (Sales Director), Manfred Thomas (Engineer), Christoph Schulze (Managing Director), Uwe Wink (Project Manager), Hans-Georg Schrey (Design & Development), Richard Leitz (Director)

An updated brochure of the energy recovery capabilities by Clyde Bergemann Termotec

has just been released. It is available for download at

www.clydebergemann.de

Richard LeitzClyde Bergemann Termotecrichard. [email protected]

Kurt RüdelClyde Bergemann Termotec

[email protected]

Hans-Georg SchreyClyde Bergemann Termotec

[email protected]

Contact Details:

17


Imtech Deutschland chooses Clyde Bergemann technology

Imtech Deutschland GmbH & Co. KG recently concluded a contract with Clyde Bergemann GmbH for the planning, manufacturing, supply, installation and commissioning of an air-cooled condenser system. This installation will be used in the new thermal recycling plant in Plymouth, a city in the English county of Devon. The order is carried out by Clyde Bergemann Termotec GmbH, the specialist for heat exchanger technology within the Clyde Bergemann Power Group.

The air-cooled condenser consists of five fan cells with auxiliary components. The condensation capacity is approx. 48 MWt at 70 mbar with 83.25 t/h steam and fulfils the very stringent sound emission requirements.

Operating company of the waste incineration plant is MVV Energie AG. Using combined heat and power, the power plant generates 23 MW heat and 22.5 MW electricity. The annual recycling rate of household waste amounts to 245,000 tons.

In May 2011 Imtech was awarded the contract by MVV for the supply of steamgenerator and water-steam-cycle including turbine and water treatment plant. The commissioning of the waste recycling plant is planned for 2014.

The complete scope of advanced burner and heating technology by Clyde Bergemann Brinkmann are presented in new brochures. The brochures are available at www.clydebergemann.de under the section Media/Downloads.

Kurt Rüdel Clyde Bergemann Termotec [email protected]

Contact Details:

New waste incineration plant in Plymouth, Southern England gets air-cooled condenser system

Partner of the steel and copper industry

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18


High Energy Efficiency Burner for emissions far below the legal requirements

Modern copper production places high demands to the process and is subject to continuously more stringent regulations regarding NOx and CO emissions. With the experience of over 130 years working in the thermal process Clyde Bergemann Brinkmann has this task accepted.

The result of the development activity is the High Energy Efficiency Burner – in short HEE.

This burner is an improved high impulse burner. The innovative technology result in an increased heat yield in the material with near-stoichiometric operation. Thanks to the formation of the flame with a significantly stronger impulse and higher exit velocity the mixing quality of oxidator and fuel is optimised. With regard to combustion technology, all kinds of stoichiometric requirements can be reproducable reached.

In view of the achieved results regarding NOx and CO emissions the most stringent legal requirements are fulfilled today and also in the future. Practical experience with the new burner proves that actual values are less than half of the values of the German TA Luft (Technical Instructions on Air Quality Control).

Due to the compact construction, the HEE burner is ideal for retrofitting.

Information about this new High Energy Efficiency Burner as well as the complete scope of supply by Clyde Bergemann Brinkmann can be obtained at www.clydebergemann.de.

Technology Seminar supporting UK Waste to Energy & Biomass markets

Clyde Bergemann Scotland had pleasure coordinating and welcoming delegates from companies from around the UK in October to the Radisson Hotel in Birmingham for a technology seminar focused on the waste-to-energy and biomass services of the Clyde Bergemann Power Group. The day achieved its aim of presenting group solutions designed to help assist plants in their strategies to increase efficiency, reduce costs and reduce environmental impact.

Colleagues from five group companies present their particular business capabilities and the wider group synergies that were possible. And from the delegate feedback reports, all presentations were very well received during the event.

The day was a huge success and has yielded many opportunities including new

relationships with four of the big companies in the industry that are currently working on new projects. Existing partnerships were also consolidated as the Clyde Bergemann Power Group demonstrated its continued commitment to technology and solutions in this market.

More seminars of this nature will be planned through 2012. Many thanks to all who took part and to Neil Manson and Charlene Alcantar who did a splendid job of ensuring the event was managed well.

Charlene AlcantarClyde Bergemann Ltd, Scotland

[email protected]

Contact Details:

Ahmad Al-Halbouni Clyde Bergemann Brinkmann, Germany

[email protected]

Contact Details:

Key contributors to the event (left to right): Wolfram Jaspers, Energy Recovery; Mike Davidson, Air Pollution Control; Stephen Young, Boiler Efficiency; Will Sullivan, Air Gas Handling and Craig Buckley, Materials Handling

19


Doncaster enterprise for learning

Clyde Bergemann Materials Handling has been presented with an award from Busi-ness and Education South Yorkshire for their contribution towards a local enterprise growth initiative.

By linking business with local educational establishments over two years, the aim was to ensure that Doncaster’s young people are aware of the skills they will need in future

employment and the opportunities that areavailable to them. In return, local business has the opportunity to understand and in-fluence the topics and methods of study in education. The result is better enterprise awareness in schools and better availability of suitable employment candidates for local businesses.

Clyde Bergemann’s contribution included school visits to give presentations and help with activities and providing work experi-ence placements for engineering diploma students. Clyde Bergemann received the award for being one of the top 20 contribu-tors from over 200 local businesses.

Annual Clyde Bergemann Power Group Sales Conference

Clyde Bergemann Power Group held their annual Sales Conference from the 17th to the 18th of November 2011 at the company’s conference center in Wesel, Germany. More than 120 key personnel attended the conference from the corporate’s global sales, marketing and R&D teams.

The sales conference provided an opportunity to share knowledge and experience of technology developments, major projects and market information from around the world. Clyde Bergemann Power Group welcomed guest speakers including Professor

Christian Rehtanz from the Technical Uni-versity Dortmund, Germany; Lode Smeets from Tractebel Engineering; Nigel Cooke from Lafarge.

Professor Rehtanz presented today’s challenges of the power transmission system to keep up with the growing feed-in of wind and photovoltaic energy. Lode Smeets presented the experience Tractebel Engineering made with numerous coal to biomass conversion and biomass co-firing projects. Nigel Cooke shared his knowledge on key issues related to the use of ash from a cement perspective.

As every year, the two days created an opportunity for learning and networking to circulate knowledge and expertise throughout Clyde Bergemann Power Group’s business fields.

The guest speakers of the Clyde Bergemann Power Group Sales conference (left to right): Prof. Christian Rehtanz, Technical University Dortmund; Lode Smeets, Tractebel Engineering; Nigel Cooke, Lafarge

Dan YoungClyde Bergemann Materials Handling, [email protected]

Contact Details:

Dan Young (right), Technology Manager Clyde Bergemann Materials Handling, receives the award from Keith Glanville, a representative of Business and Education South Yorkshire

20


Events Diary

Editorial

Publisher:

Clyde Bergemann Power Group Inc.

News Editors:

Stacy GentryClyde Bergemann Power Group Americas, USAeMail: [email protected]

Lydia HowesClyde Bergemann Auburn, USAeMail: [email protected]

Sonja MayerClyde Bergemann GmbH, GermanyeMail: [email protected]

Printing:

DWS Offsetdruck GmbHHerford, Germany

Ralph Ludwig (left) took over the position as Managing Director of Clyde Bergemann Germany and for the entire CBEUI division. He follows Bernhard Rogalla (right), who is now acting as Director Project Development & Contracting and Business Development for the entire CBEU division.

Personnel Developments

Dr. Patrick von Hagen took over the position as COO of Clyde

Bergemann Power Group RoW. He will cover this new function beyond his current position as Group Corporate Finance Director.

Sascha Herzmanatus joined Clyde Bergemann Power Group as Business

Control Manager. In this position, he strengthens the Group Finance function.

Date Name of event Location Participation of Clyde Bergemann

April

April 2-4, 2012 BLRBAC Atlanta, GA

April 23-25, 2012 NAWTEC Portland, ME Clyde Bergemann Power Group Americas exhibits

May

May 8-10, 2012 VGB Keli Berlin, Germany Clyde Bergemann Wesel, Germany exhibits

May 15-17, 2012 Electric Power Baltimore, MD

May 21-23, 2012 CIBO Fluidized Bed Combustion Conference Raleigh, NC

June

June 12-14, 2012 POWER-GEN Europe Cologne, Germany Clyde Bergemann Power Group exhibits

June 19-22, 2012 Air & Waste Management Association San Antonio, TX

July

July 16-17, 2012 Reinhold APC Conference & Expo Baltimore, MD

July 30 -August 2, 2012

CIBO Industrial Emissions Control Conference Portland, ME

August

August 15-17, 2012 Coal-Gen Louisville, KY

August 20-23, 2012 MEGA Symposium – Air Pollutant Control Baltimore, MD Clyde Bergemann Power

Group Americas exhibits

October

October 10-12, 2012 VGB Congress Power Plants Mannheim, Germany Clyde Bergemann

Power Group exhibits

December

December 11-13, 2012 POWER-GEN International Orlando, FL Clyde Bergemann Power

Group Americas exhibits

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