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7 UK ACTIVITIES This chapter reviews the prospects of UK manufacturers in the global HRSG market, and their capabilities. Areas of current research, development and demonstration (RD&D) which are being undertaken in the UK are indicated alongside recommendations of areas of significant future focus. 7.1 Prospects of UK Suppliers and Manufacturers in the Global Market Large, new build HRSG manufacture, as with many other heavy engineering manufacturing business within the UK, is finding it increasingly difficult to compete with the low costs associated with both European competition based on the continent (e.g. in Italy and Spain) and the significantly reduced outlay incurred by manufacturing in East Asia. With more modular HRSG designs becoming commonplace, the future of UK HRSG companies in the new-build market lies in the ability to sell, supply and assemble HRSGs, based on their own designs and advanced technologies, albeit that the standard components may not necessarily have been manufactured inside the country. Within such an environment, licensing agreements and collaborative partnerships are therefore deemed essential in order for companies to maintain the ability to compete in the global market. In order to form such alliances, UK companies must be in a position to offer something in return. Under such conditions the requirement to be continually developing new technologies becomes vital. Therefore to guarantee future long-term prospects for UK suppliers and manufacturers in the global market, its knowledge and development of leading edge technologies must be maintained. 7.2 UK Capabilities in HRSG Design, Manufacture and Supply – Utility-Scale In terms of UK based large utility HRSG manufacture and design, Mitsui Babcock has a significant presence within the UK. Mitsui Babcock is a major energy engineering company incorporated in the UK and since 1995, a wholly owned subsidiary of Mitsui Engineering & Shipbuilding of Japan. The company is a technology leader in large fossil fuel steam generating plant, and specialises in the design, engineering, manufacture, construction, commissioning and after sales servicing of high efficiency, high availability coal, oil, and gas fired boilers for the power stations of electricity generating companies world wide. The company is also a major manufacturer and supplier of heat recovery steam generating plant, industrial fluidised bed and other clean burn coal fired boilers, coal milling plant, flue gas desulphurisation plant and low NOx technologies. (118)
Up until the mid 1990’s and operating at the time as Babcock Energy, Mitsui Babcock was one of the worlds foremost suppliers of HRSGs. In 1993 Mitsui Babcock were nominated as the “worlds leading supplier of HRSGs” and were winners of the coveted Power Engineering International “project of the year award”. To date the company has won contracts in some 23 different countries. However by the mid 1990s the HRSG market suffered a severe downturn with limited opportunities and reduced margins. To compound this, the market was migrating from assisted circulation to natural circulation designs and the company’s specific technology offering became less competitive. However with a recent upturn in the fortunes of the HRSG market particularly in America, Mitsui Babcock have enhanced their product range by concluding a licensing agreement with Babcock Hitachi KK for natural circulation designs. Significant orders for utility plant HRSG supply such as the natural circulating HRSG for Naco Nogales power plant in Mexico and the assisted circulated HRSG employed at Blackpoint power station in China have been completed. Mitsui Babcock employs approximately 3000 people in its various operations in the UK and abroad. Its headquarters are at Crawley in the UK but operates locally with regional operations elsewhere in the UK and around the world. The company’s strengths lie in its depth of engineering capabilities, its technology base, its extensive manufacturing facilities, its considerable experience in site erection, commissioning and servicing of major power plant in countries across the world and its ability and experience in managing very large multi-disciplinary projects. The company’s combination of technological, financial and skill resources enable it to deliver projects in a range from £10 million to £400 million, anywhere in the world. Thermal Engineering International Ltd – Greens is the largest independent manufacturer of utility HRSG’s in the UK. Originally known as E Green & Son the Wakefield based company has amassed over 150 years of experience in the field of heat recovery since its founder Edward Green invented and patented the world’s first economiser which he patented in 1845. TEI Greens has manufactured Utility HRSG’s for most of the world’s leading boiler designers/makers as many no longer support their own manufacturing facilities. TEI Greens has been successful in manufacturing HRSG’s for domestic and export projects and has a wide experience of different designs including vertical and horizontal gas types and once through designs. Currently, around 40% of all the UK’s utility HRSG’s have been manufactured by TEI Greens. TEI Greens are holders of the ASME S & U stamps and have a large facility of over 100,000m 2 with extensive workshops. It has 3 x High Frequency Finning machines in its Wakefield Factory (10 worldwide) for the manufacture of high frequency welded helical fin tubes as used in modern HRSG’s. The facility is capable of producing over 120,000 tubes and 10 major HRSG’s per annum. (119)
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