: latest equipment innovations for lcpd colin blackmore/mark davidson sick (uk) ltd aqe conference...

: Latest Equipment Innovations for LCPDColin Blackmore/Mark Davidson SICK (UK) Ltd

AQE Conference March 2013

: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013

SICK process automationIndustry overview

2

Oil & gas

Power

Pro

cess

Em

issi

on

Cement Metal & steel

Chemical Petrochem &refineries

Pulp & paper

Waste


SICK process automationScopes

Measuring devices and system solutions for continuous emission monitoring

• Entire product range for all requirements

• In situ and extractive measurement technologies

• Solutions for all industries and legal regulations

Emission

Analyser for a variety of process measurements

Process

• Compact transmitters with 1 to 2 measuring components

• High-performance analysers with up to 4 measuring components

• Multi-component analysers > 4 measuring components

Measuring devices for tunnel monitoring

Tunnel

• Rugged measuring devices with 1 to 3 measuring components

• Measurement of air quality and visibility

• Early fire detection

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Equipment for LCPD

: Process gas analysers- DeNOx process monitoring and control equipment

: Continuous Emission Monitors - General Gas Analyser systems for Coal, Gas, Oil Power Stations- CCGT Plant and measurement of low levels of NOx- Mercury monitoring in Coal-fired Power Stations (separate

Workshop presentation)


DeNOx Plant

Gas preheater FGD EP

Air preheater Boiler

Water

FGD plant

gypsum

Limestone

Ashes Slag Coal Air

Ammonia DeNOx

reactor EP


Why do we want to measure?

With the help of a catalyst, NO and NH3 react to N2 and water:

4 NO + 4 NH3 + O2 4 N2 + 6 H2O

NO measurement is important for the process control: a) raw gas before catalyst : to calculate the NH3 injection rate based on the “NO load” b) check catalyst efficiency and NH3-trim

Application SCR DeNOx Plant

1


Technical Data:

Measuring Range:

before SCR: up to 1,500ppm NO depending on burner technology

after SCR : up to 100ppm NO depending on local regulation

gas temperature: 340 ... 420°C

high dust : typically 15g/m3

duct size: typically 5m (1.5 .... >6m)

Application SCR DeNOx Plant

1


Extractive Technology Challenges

: Multiple Sample Probes with graded entry holes to try and balance the sample flow across large ducts and ensure accurate measurements

: Standard extractive CEM system with Filtration, Cooling, Sample Switching

Problems

- very high dust burden

- high maintenance load on Sample Systems

- unreliable systems


In-situ Technology Challenges

: Cross duct not practical due to high Dust Burden, extinction of signal in large ducts

: High temperature application

: Sick Solution – extract sample and measure with small path length- Orientate probe so as to avoid large particles being captured- If 15m/sec flow achieved then remaining dust stays in

suspension- Dust shows as general extinction, which can be calibrated out


GM32: The extended In-Situ solution


>>> DOAS

Differential Optical

Absorption Spectroscopy

Wave length

Ext

inc t

ion

SO2

NO

NH3

NO2

<-- 190 nm --> 400 nm

GM32 - optimized measuring value evaluation

Absorption curves of SO2, NO, NO2 and NH3

: Evaluation principle DOAS with sophisticated algorithms

: No influence of dust, droplets, humidity and other gases

: In-situ >>> delay free

: High and stable accuracy for high and low measuring ranges


GM32 - Optical System - Control Cycle

: Advantages:

- Automatic self test Basic,Pro and upon request

- Check of zero Basic,Pro and span Pro for each component. ▪ No test gases required.

- Compliance to EN 14181, EN 15267-3▪ QAL3 zero & span values Pro

▪ TÜV approval Pro

- Interval adjustable Basic,Pro

: Pro Version with filter wheel

: Basic version without ~ - no difference in quality of measurement


GM32SCR De-NOx control


CCGT plants - CEMs


Power

Combustion air

Power

Gas

Generator

Generator

Flow

Steam turbine

Gas turbine

Cooling air

Heat recovery steam generator

Steam

Data Acquisition system Cem View or

MEAC2000

FLOW

Stack

CO NOx,, O2,


Application: CEMS for CCPP

: Extractive Technology : In situ Technology

PowerCEMS100

Gas

CO, NOx, O2, option SO2, CO2

FLOWSIC100

Flow


Minimum Requirements / Recommendations

: Gas components

-Nitrogen monoxide (NO) + Nitrogen dioxide (NO2) = “NOx as NO2”

- IR not low enough ranges for NO

- Carbon monoxide (CO) - Oxygen (O2), correction to reference conditions

: Option - Sulfur dioxide (SO2), Carbon dioxide (CO2)

: Flow measurement

: Data acquisition system according to the EN or US EPA requirements


Best Solution: PowerCEMS 100

MAC800 compact system PowerCEMS 100 GMS 830 and 831 analyzer modules

sample gas cooler

Control unit

BCU


PowerCEMS 100

Certified according to EN 15267-2 and EN 15267-3 to be used as AMS for CCPP

Compliant to EPA Part 60 and Part 75 CEMS requirements for gas fired power plants

Single central operating unit (BCU) for easy operation

No NOx converter for better measurement accuracy and lower cost of consumables

Low level CO monitoring done by field proven UNOR best accuracy of any NDIR on the market.

Compact, suitable for wall mounting

Interface to DAS or DCS via Modbus or OPC or hard wire, adaptable to customer’s requirements.


Best Solution: Flowsic100

Flue gas temperatures up to 450°C

High accuracy even at gas velocities near zero

Corrosion resistant Titanium transducers as standard

Representative measurement using cross-stack

version


Why is DEFOR better than Chemiluminescence ?

Continuous individual measurement of up to 3 components NO, NO2 and SO2

No interference from background gases (H20 and CO2 show no absorption in the UV range)

Adjustment unit for calibration of DEFOR without using test gas

No Converter, No Ozone = less trouble


GMS800 Advantages

: No need to use a NOx converter, change converter cartridges

: User-friendly analyzer system

: Designed for lower maintenance: simple single-point linearization, excellent thermal stability

: With the UVRAS principle low ranges of NO, NO2, SO2 (0 - 25 ppm) can be accurately and individually measured.

: Using the NDIR principle to measure CO in low ppm ranges (20 ppm) can be achieved. New Mounting of the NDIR bench on rubber supports reduces vibration sensitivity.

: Using the paramagnetic measuring principle to analyze O2

: Latest cold dry CEMS analyzer technology UNOR & DEFOR with an excellent value for CCPP


Emission monitoringApplication-specific fully configurable system

Dust, volume flow (in situ)

All required gas components (extractive)(SO2, NO, NO2, NH3, HF, CO, CO2, CH4, HCl,N2O, H2O...)

Connecting additional networks using standard interfaces

High-grade analyser modules and components

Central control unit

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: Thank you for your attention.

: latest equipment innovations for lcpd colin blackmore/mark davidson sick (uk) ltd aqe conference...

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