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Gasifier Balance of Plant (BOP) Components: Global Markets

  • September 2014
  • -
  • BCC Research
  • -
  • 475 pages

Summary

Table of Contents

This BCC Research report characterizes and quantifies the world markets for gasifier balance of plant (BOP) components in terms of unit shipments, regions, and market dollar value. CAGR projections are given for the period 2013 to 2018.

Use this report to:
- Characterize and quantify the world markets for gasifier balance of plant (BOP) components in terms of unit shipments, regions, and market dollar value.
- Gain an insight into the market drivers that are raising or inhibiting demand for gasifiers market structure, including segments and subsegments.
- Examine gasifier BOP components and their markets throughout well-delineated regions of the world.
- Analyze Gasification and gasifier balance of plant component technologies.

Highlights
- BCC Research estimates the global market for gasification balance of plant (BOP) components totalled $55.1 billion in 2013. The market should reach $73.2 billion in 2014
and $96.1 billion in 2019, registering a compound annual growth (CAGR) of 11.8% over the next five years.
- Gasification as a segment will grow from $18.7 billion in 2014 to nearly $25.9 billion by 2019 at a 14.7% CAGR for the period 2014-2019.
- Whole-system components (air separation unit and heat recovery steam generation) is the largest segment of the global market for medical device technologies and it has reached $29.6 billion in 2014 and is expected to reach $33.8 billion by 2019, increasing at a CAGR of 9.9% from 2014 through 2019.

INTRODUCTION
The rise of gasifiers as core processors of carbonaceous matter in many useful products is enabled by a variety of “balance of plant” equipment (BOP). These components are used to move, size, measure, and deliver feedstock into gasifiers; provide heat and raw oxygen and nitrogen to shape the molecules that the gasifier produces; and keep the gases from exploding before their work is done. Other BOP components cool the product gases; clean them and capture the contaminants; extract heat and reuse it; and carry away the remnant unchangeable material that even the superheat within a gasifier cannot change.

The world market for BOP components for gasifiers has grown to be tens of billions of dollars per year. BOP components are thus forming a new major industrial sector.
What has somehow been missed by mass media and the watchers of the World Wide Web is a commitment that the Chinese have made to take themselves out of the
climate equation. They have no easily accessible indigenous fuels in the ground except billions of tons of coal. With this resource, they must supply energy and raw industrial
chemicals to their factory economy, keep the lights on and the food cold, power their share of the Internet, run their commuter trains, and make a good portion of
everything that the world uses.

To extricate themselves from the hazards of such massive use of coal, China is in a frenzied process of deploying a giant fleet of new power and chemical coal-converting
gasifiers on a scale that would not otherwise be seen except in the event of a big war. China is going to capture all of the emissions; extract what can be useful, such as
elemental sulfur; and pump the rest of it miles into the ground in the thousands of holes it has prepared. A good portion of the gasification system that China uses to perform these miracles of saving themselves from themselves and the rest of us and the world’s atmosphere as well will originate in the U.S. and Europe. There has been a sharing of technology development and experience going on for the past half decade, all leading to the current critical cusp in the history of our livable climate.

China has learned to build some fairly powerful gasifiers, but nothing on the scale of the behemoths being produced by industrial giants such as GE, Shell, Siemens, ThyssenKrupp, and others. Therefore, the heavy lifting to change the energy and chemicals infrastructure will be done with imported equipment. Each installation will be
a billion-dollar enterprise. Hundreds will be—in fact, are being—built. Further, every installation includes BOP components whose market value is worth at least as much as
the 24-story-tall matter-manipulation machines.

Perhaps equally as important, these same gasification equipment complexes are now being deployed elsewhere. Governments and private industries are using them to
make gasoline from corn stalks, to power villages with garbage, to siron ore, to destroy chemical weapons, to manufacture medicines from coal, and to heat and power
university campuses. Saudi Arabia is installing a small cadre of large gasifiers to convert a mountainous stockpile of what are called residuals—the stuff that refineries
cannot use from a barrel of crude—and to thus power a refinery and a nearby city, all with reduced emissions. This report from BCC Research takes a quantitative look at all of the support equipment, specifically those BOP components, that are needed so that the gasifier can do what it is intended to do without harming the environment. The analytical approach taken in these pages is to examine the total markets and trends for BOP components that serve either the whole gasification system or one of the three stages of the process: pre-gasification, gasification, and post-gasification.

What became evident rather quickly in the development of this report is that each stage of the gasification process requires BOP components that, taken together at that
stage, are part of a multibillion-dollar-a-year industry. All of the system components, which are air separators and heat recovery steam generators (HRSGs), can cost as
much as the gasifier itself To put the market analysis in context, the world markets for the BOP components are quantified for each major gasification application segment as follows:
- Coal to energy (CTE).
- Coal to liquid (CTL).
- Petroleum coke (petcoke)/residuals.
- Direct reduction of iron (DRI).
- Biomass to energy (BTE).
- Biomass to liquid (BTL).
- Waste to energy (WTE).

The market analyses lead to quantitative forecasts of market evolution through 2018, expressed in terms of the number of units that will be sold and the market values of
those units. Where appropriate, qualitative arguments are presented to enhance the understanding of the underlying political, environmental, economic, and technical
frameworks in which the markets for gasifiers and their associated BOP components will be used (or not be used). The report includes descriptions of the functions and purposes of a half dozen to a dozen individual BOP component types for each gasification stage. Equipment whose markets are quantified include conveyors and hoppers, gas compressors, air separation units (ASUs) and HRSGs, different types of gas filters, plasma torches, lockhoppers, truck tippers, buffer bins, acid gas removal systems, CO2 capture systems, gas quenches, and others.

What was most surprising, probably because of the imposing nature of gasifiers themselves, is that the world market for BOP components was already more than $40
billion annually in 2013. That figure will double by 2018. The projections for BOP components are derived from updated figures that were provided in BCC Research report EGY106A Global Markets for Gasifiers. The gasifier market and project development ecosystem are extremely dynamic. Extensive revisions were performed during development of this report in order to account for the substantial number of gasification projects that were canceled in Europe and the U.S. in the past year and the greater number of new projects that were discovered to be in development. All the markets for gasifiers in each of their application segments are increasing by double-digit percentages annually. The bottom line is that gasifiers have become a mainstream product, and their BOP components are already a multibillion-dollar-a-year
diversified global industry on a sustainable growth path.

STUDY GOALS AND OBJECTIVES
This report was written to characterize and quantify the world markets for gasifier balance of plant (BOP) components in terms of unit shipments, regions, and market dollar value. Gasifier technologies have been evolving for well over a century, but only recently have emerged as being economically and technologically viable, and in many ways preferable to other energy-conversion devices. They are often short-list choices for the production of syngas and chemical feedstocks on an industrial scale and energy sources for a variety of smaller regional, municipal, village, and commercial or residential sectors. A growing number of opportunities also exist where gasifiers are a
de facto choice for syngas production, even from natural gas.

The contributions each type of BOP component brings to the gasification process are examined, including alternative equipment that is selected based on the function and
feedstock of the gasification system with which it is used. This report is constructed to quantify the markets for BOP components in terms of the gasification stage in which
they are used, whether they are whole-systems devices providing services at each stage of gasification, or are part of a pre-, during-, or post-gasification process. Any market analysis report involves detecting and revealing trends. This report is specifically focused on examining the slope of the market value of each component type considered, and in aggregate portrays the market trajectory through units that will be sold and the dollar market value of those shipments. The values were determined for individual component types, as was the aggregate value of the gasification stage BOP components as a whole; these were rolled up into five global regional groupings, and, lastly, as a world total market dollar value for BOP components by gasification stage.

This report summarizes the market drivers that are raising or inhibiting demand for gasifiers, including the rush to build an entire clean energy baseload infrastructure in
China. Although that is the dominant gasification market on the planet, it is shown that it is not the only geographically distinct market for utility-, industrial-, and
commercial-scale gasifiers.

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