510 glass and ceramic industry en - eco monitoring€¦ · the promecon systems allow significant...

ECM ECO Monitoring, a.s., Nevädzová 5, 821 01 Bratislava, Slovak Republic

Phone: +421 2 4342 9418 E-mail: [email protected] Company Reg. No.: 17312094 +421 2 4342 7408 http:// www.ecomonitoring.com VAT No.: SK2020317244

Fax: +421 2 4342 7465

Environmental & Process Monitoring instrumentation & systems

Glass and Ceramic Industry

ECM ECO Monitoring, a.s. Bratislava ( Slovak Republic ) is focal company of the ECM Group consisting from a network of

subsidiaries to offer an optimal technical and comercial support on field of monitoring instrumentation of gases, liquids

and particles.

For the Glass and Ceramic Industries ECM is offering:

• Monitoring of O2 or CO to control furnace atmosphere

• Heat value, Wobbe index, composition of fuel gases

• Mass flow of fuel gas and combustion air

• Filter watch – efficiency of filtration systems

• Working area monitoring

• Water quality monitoring

O2 and CO monitoring

For O2 monitoring the classical way is to use Zirconia dioxide based analyzers.

For glass and ceramic applications these instruments must be designed for up to 1700°C process gas temperatures.

Problem of in-situ oxygen analyzers is response time getting slower dues to filter plugging. The proven semi-extractive

probe design is circulating the sample into the actual sensor module located on outer side of the probe flange. In this

circulating stream a flow sensor is monitoring the instrument response time. The arrangement is also allowing to monitor

CO by means of a catalytic cell.

In some cases a tuneable diode laser is the best solution for O2 and CO monitoring. Adventage of the TDL instruments is

monitoring on a long path better representing the process conditions.


Phone: +421 2 4342 9418 E-mail: [email protected] Company Reg. No.: 17312094 +421 2 4342 7408 http:// www.ecomonitoring.com VAT No.: SK2020317244

Fax: +421 2 4342 7465


Calorific Value Analyzers

Calorific value analysers are to monitor natural gas, petrochemical waste

gases, coke gas, blast furnace top gas, biogas .

ECM is offering several solutions:

Miniature gas chromatographs for analysis of gas compositions and

caloric value of natural gas. An accurate instrument optimized for any

natural gas related application.

Catalytic oxidation based analyzers to monitor Wobbe index or calorific value

of flammable and even on flammable gases.


Phone: +421 2 4342 9418 E-mail: [email protected] Company Reg. No.: 17312094

+421 2 4342 7408 http:// www.ecomonitoring.com VAT No.: SK2020317244

Fax: +421 2 4342 7465


Combustion Control Systems

The Promecon systems allow significant optimization of the thermal processes such as coal fired boilers,

smelter processes, cement kilns and others. Using innovative technologies emissions are reduced, efficiency

and availability of plants are entranced.

The Promecon optimization system is utilizing several innovative sensor products:

• Cross correlation based combustion air flow sensors working

reliably in harshest conditions for up to 40m/s flow speed and up

to 1100°C temperature.

- No calibration needed - No drift, no cleaning

- Not affected by high dust

• SIL2 available coal mass flow/velocity/particle size measurement

- Long life ceramic sensors

50-10 000 g/m3 concentration

0-100 t/hr mass flow

10-60 m/s velocity

30-60 um particle size - Different probe length, ATEX

• Fast responding temperature sensor on mill classifiers without abrasion.

• Online unburned carbon measurement.

This is the World most sold fly ash analyzer.

- Lab accuracy in process

0-20% carbon in fly ash

2-10 minutes measuring cycle




Fax: +421 2 4342 7465


System Application for Boiler Optimization

� PROMECON is a total solution provider for Boiler optimization.

� Patented, unique online measurement systems for PF/ Biomass, PA, SA, OFA, particle size distribution,

carbon in fly ash and other parameters.

� Evaluation of pulverizer, coal pipes, air ducts, boiler, APH.

� Improved control concepts for increased load gradient, low load operation, multifuel burning etc.

� Our references are our (PROMECON) references. Installed basis > 2000 sensors.

� All designed and made in Germany.

� Tuning through measurement and control (APC).

� We handle complete projects, CFD, modification of ductwork, trimming dampers, optimization.

� Typical projects: Plant assessment, Efficiency testing, Boiler optimization, Advanced process control.

� Field of projects: Pulverizer, coal/air distribution, combustion, fluegas.




Fax: +421 2 4342 7465


Personal samplers

Personal samplers to trap different fractions of particles, but also gas compounds during a working shift

for a laboratory analysis of risk factors employees are exposed to. The battery controlled pumps have a

built in flow control and belt or clothing fixation. Broad range of filters, absorption traps and other

accessory.




Fax: +421 2 4342 7465


Toxic and combustible gas detectors

Broad range of stationary and portable toxic and flammable gas detectors. The instruments can be

provided with a wireless transmission with a several kilometres range.

Instrumentation allowing to set up in few seconds an accident site. The emergency team control has a

permanent information about the risks the members are exposed to. Stationary systems can be installed in

few minutes without any need of obstaculous cable connections.

Higher category of the instrumentation allows reliable detection of almost all kinds of hazardous

gases.

• Personal monitors

• Site survey instrumentation

• Portable instruments

• Fixed instruments




Fax: +421 2 4342 7465


• Wireless infrastructure

• Software



+421 2 4342 7408 http:// www.ecomonitoring.com VAT No.: SK2020317244 Fax: +421 2 4342 7465


Continuous Emission Monitoring Systems (CEMS) For continuous emission monitoring systems usually monitored compounds are:

SO₂ HCl Particles H₂S

NOx HF Flow TRS

CO NH₃ Pressure CO₂

CxHy O₂ Temperature

ECM is providing stack gas monitoring systems based on all currently available architectures:

• Straight extraction

• Dilution

• In-situ

Instrumentation offered for European clients is QAL1 certified.

The gas monitoring instrumentation is based on proven techniques:

• NDIR

• UV absorption

• UV fluorescence

• Chemiluminiscence

• FTIR

• Tuneable laser diodes

• FID

The QAL1 certified particle monitoring instrumentation is based on opacity, light scattering, tribo, or

electrodynamic methods.

Flow monitors are based on following methods:

• Ultrasonic

• Anubaric

• Thermal conductivity

The ECM Data systems are fulfilling all legislative requirements including the QAL3 support defined in

EN 14181 standard.





Flame detectors and ignitors

Flame detectors and ignitors for various fuels and combustion chambers





Oxygen monitoring Flue gas

• Tuneable laser O2 / CO analyzers for large boilers

• Zirconia and catalytic CO

Main adventages

• Yearly calibration interval

• Same analyser for 150°C - 1500°C temperature range

• Combination of laser and Zirconia probes allows safe detection of areas with excess or lack of

oxygen in combustion process

• Our laser monitors allow to use air purge instead of usual nitrogen to keep the optics clean





Process gases

Broad range of paramagnetic, zirconia, optical or electrochemical analyzers from trace

concentrations up to oxygen purity monitoring around 100% O2 concentration.

The main applications are:

• Clean industrial gas production

• Oxigen content in different process gas mixtures

• Inertization processes

• Working area safety





Baghouse Filter Monitors

The maintenance of modern bag and cartridge filter systems is normally both a time consuming and costly

activity often undertaken in unpleasant conditions with limited available time. To overcome these

problems, PCME supply an advanced Predictive Monitoring Solution used in conjunction with some of the

world's most advanced particulate measurement systems.

Preventative, Cost-saving, Maintenance Enhancements

Bag House control enhanced by Electrodynamic filter management

Although particulate monitoring systems are generally purchased to monitor environmental emissions to

atmosphere, many users also utilise these instruments as preventative maintenance tools.

The ability to predict when a filter is likely to fail and to be able to identify which row or chamber is at fault

has provided users with a proven method to not only reduce the environmental impact and clean-up costs

associated with large-scale emission events but also to make significant savings in spares, maintenance

times and lost production.

Normally filter media is changed on a regular basis, typically based on experience or on the filter

manufacturers recommendations. This can be both costly and time-consuming, resulting in either filter

elements being changed when there is still serviceable life to be had or alternatively the bag house is run

too long resulting in particulate leakage and eventually gross filter failure.

To enable users to achieve the longest possible service life from their filters without the worry of

catastrophic failure, PCME has developed a suite of advanced software to be used in conjunction with

selected Electrodynamic-based particulate monitors.

PCME’s patented Electrodynamic sensors offer the most dynamic sensing technology currently available.

Their unique non-contact charge-induction measurement technique provides the capability to remotely

access the filters cleaning signature by accurately tracking the very dynamic dust emissions created during a

bag filter cleaning cycle.





As a filter is reverse jet cleaned, any defects in the filter membranes are exposed resulting in relatively high

dust peaks. By monitoring these peaks in realtime using PCME’s Predict software package, it is possible to

identify potential problems within the filter before they result in breaches of environmental limits. Marker

pulses generated from the filter's cleaning system allows easy identification of damaged rows.

Electrodynamic Sensor used for Predictive Filter

Maintenance

The use of filter performance monitors in conjunction with Predict and Ethernet connectivity allows for the

first time the possibility of truly remote observation of the condition of both bag and cartridge filters. Used

in conjunction with low level emission warning alarms, it allows the remote inspection of filter elements

before dust emission levels breach regulatory limits, thereby allowing scheduled maintenance and

eliminating the lost production time normally associated with unplanned plant stoppages.

The Deterioration of Row 10 is highlighted in real-time before environmental limits are breached

The above graph, down-loaded from an Electrodynamic instrument illustrates some of the capabilities of this

system. The sensor, which was originally fitted purely as an environmental monitor is installed in the outlet

stack of a 10-row bag filter, each row comprising 20 bags.





The bags in this particular filter were traditionally replaced annually as recommended by the filter

manufacturer, however, in this instance the plant's maintenance department fitted an Electrodynamic

system instead and left the old filter elements in place. After several months, an increase in Bag Leakage

Trends was identified and low-level alarms alerted plant operators to increased emissions from the filter.

This information was made available to plant, environmental and maintenance departments simultaneously

via an Ethernet connection to the instrument. The

advanced warning of filter failure allowed the maintenance department to schedule the fitting of

replacement filter elements.

This has the following benefits:

• Reduction of lost production time

• Identification of row failure allows the use of fewer

replacement filter elements

• Labour time and costs are both reduced

• Service life of the majority of filter elements has been

greatly extended

• Filters are now checked post-maintenance to ensure that all

bags are correctly fitted and have not been damaged during

installation

Electrodynamic Sensor installed in bag house outlet

Over a period of time, Predict has helped to highlight a further problem with the

filter. It was

noted that gross filter deterioration was always apparent in the same two rows and

as a result

of this, the gas stream inlet to the filter was modified resulting in more even wear

and extended filter life.

The ability of the instrument's control unit to input 4-20 mA signals from other

devices has allowed the system to be used in conjunction with pressure drop

devices to monitor the caking of the filter bags allowing the optimisation of the

cleaning cycle reducing both compressed air usage and bag wear.

This instrument, although originally considered as just an Environmental purchase is now regarded as an

integral filter maintenance tool and the system has been expanded to monitor a further 8 filter systems,

providing not only environmental protection but also reduced costs and increased production.

A Cement Kiln Baghouse incorporating an Electrodynamic filter management system

Multi-chamber bag filters are becoming more and more common throughout industry. Regulatory

demands reducing the amount of particulate emitted from a wide range of processes are resulting in their

installation to replace both Electro-filters on existing sites and to provide the prime dust filter solution in

new applications.





The decision to install filter management systems is driven by the need to not only be able to fully

understand the operation of the filter system, but also to be able to improve plant efficiency and in

particular to ensure that the functionality of these filters can be controlled and maintained so they may

operate at their optimum performance levels.

Pro-Scatter and Electrodynamic Main Stack Sensors

Modern high efficiency bag filter systems typically employed on such processes such as Municipal Waste

Incineration, Cement Kilns and Steel Manufacturing emit very low levels of particulate, typically single figure

mg/m3 levels. To effectively monitor such low levels PCME employ either Electrodynamic or Pro-Scatter

technologies on the main stack.

Both techniques are able to measure extremely low levels of dust, down to 0.01 mg/m3, but they are

generally unable to indicate exactly where the leak in a multi-compartment filter has occurred. To

overcome this problem, a secondary filter management system is used.

Employing Electrodynamic trending sensors in each compartment of a multi-chamber bag house allows

plant

operators to observe the real-time changes in base line emissions and to have instantaneous, plant-wide

access to the functionality of their filter systems.

These systems also allow the potential for total control and performance optimisation of the bag house.

Both stand-alone systems and bespoke plc interfaced solutions to connect directly to users control systems

are available. Communication protocols include AB DF1, Ethernet/IP, Modbus ASCII, RTU and TCP.

These options provide seamless integration into existing network operating systems.

Electrodynamic sensor installed directly in Baghouse compartment wall

The cost benefits of these networked filter management systems have been proven on large bag house

applications in industrial applications worldwide, the systems providing payback in less than 12 months.

Benefits include:

• Remote sensor conditioning checks

• Diagnostic notification of failed valves (solenoid and diaphragm)

• Real-time leak detection by compartment or row

• Prediction of filter failure

• Suspension of individual filter row cleaning

(provides temporary decrease in emission base line trends)

• Reduction in compressed air usage/increase in compressor life

• Reduction of maintenance times/costs

• Potential for increased operational life of bag filter elements





Natural Gas Composition Analyzers

Overview

As natural gas is expanding in the world’s energy balance, there is an increasing need to measure

flows and other gas parameters with the highest accuracy. Heat Value Gas Chromatograph

HGC303 offers the world’s top class technology to analyze natural gas and calculate derived

parameters.

Features

Field mountable

Compact and rugged design for field installation

without need for

conventional analyzer housing.

Packaged natural gas analysis application

Ready-to-start standard application with gas

components

concentrations, heat value and other parameters, all

in accordance to ISO standards.

Fieldbus communication

HGC 303 is compliant with Foundation Fieldbus for effective data and self-diagnostic

transmission as well as configurat ion/maintenance communicat ions. M odbus

communication is also provided.

Environmental friendly design

Designed in accordance to ISO14001, the global standard for environmental protection.

Low cost of ownership

A low priced gas chromatograph with reduced engineering, installation start-up and maintenance

costs. Validates the purchaser’s decision by assuring effective savings in natural gas consumption

management.

A compact analytic system to monitor heat value density, Wobbe index and other compounds for direct instalation in pipes without a need of any sampling system, shelters, carrier or calibration gases.

Orbital Compact Gas Properties Transmitter Integrated System

GasPTi™ is a comprehensive, revolutionary and most importantly, fast response instrument. The PTi provides





accurate, real-time monitoring of the key physical properties of natural gas including: CV/BTU, Relative Density,

Wobbe, Compressibility, Motor Octane Number, Carbon Dioxide and others. GasPTi’s unique and proven

technology has been implemented in numerous installations across the world with many globally recognized

organizations.

Technology recognised in standards as valid for custody transfer in US (AGA 5) and EU (OIML R140)

Benefits

• Easy to install, configure and operate – Installation of full system typically less than 2 hours

• No on-going analyser maintenance or technical support needed - simple annual validation

• No carrier gas - eliminates safety concerns and availability of helium or hydrogen storage

• No continuous calibration gas - eliminates need for cylinder storage and rental

• Reduced uncertainty - near real-time CV data matching, instantaneous flow measurement

Standard options

• GasPTi-P Post-mounted with optional remote sample probe

• GasPTi-F Fixed Probe direct pipeline-mounted version

• GasPTi-R Post-mounted with retractable sample probe

• GasPTi-FF Fixed Probe high speed direct pipeline-mounted version

Description

GasPTi derives a simplified equivalent 5-gas mixture from which it utilizes the standard ISO6976 gross

characterization method to calculate the gas quality parameters. For sampling, the patented VE Technology™ sample

probe eliminates vortex shedding and the need for vortex shedding calculations. This allows you to utilize any length

of probe to ensure a representative sample is taken from the centre 1/3 of the pipe. In addition, its aerodynamic tip

actively rejects particulates to allow significantly reduced filtration and improved accuracy. The integrated gas

conditioning system provides filtering, temperature, pressure reduction with full Joule-Thomson protection and flow-

control, which when pipeline mounted provides fast, accurate sampling and measurement.





Health and safety instruments

510 glass and ceramic industry en - eco monitoring€¦ · the promecon systems allow significant...

Documents