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: WID Process Gas AnalysisColin Blackmore/Mark Davidson SICK (UK) LtdAQE Conference March 2013
: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
SICK process automationIndustry overview
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Oil & gas
Power
Proc
ess
Emis
sion
Cement Metal & steel
Chemical Petrochem &refineries
Pulp & paper
Waste
: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
SICK process automationScope
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 analyserswith 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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: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
Process measurements in WID
: Raw Gas analyser systems- Multi-gas systems- Single gas measurements
: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
Raw Gas Multi-gasMCS300P – Compact, Robust and Efficient
: Main Characteristics
- Extractive IR/VIS process photometer▪ Wavelength range from 300 nm up to 12.000 nm
- Process monitoring in gases and liquids- Multi component application
▪ max. 6 components normally- Applicable in hazardous areas- Flexible process cell concept- Flexible measuring ranges
▪ From ppm up to high Vol.%- Adjustment filter wheel to avoid calibration gases (optional)
: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
MCS300P – Measuring Principle
- Single beam photometer- Dual wavelength technique- Gas-filter correlation method
: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
MCS300P – Assembly
: Compact Design- Easy access to all sub assemblies
: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
MCS300P – User Advantage
: Adjustment filter wheel (Option)- Adjustment and drift control without test gas- Saves money and time Adjustment filter wheel
: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
MCS300P - User Interface Concept
Ethernet ConnectionDirect or via network
Remote diagnosisRemote maintenanceRemote operation
Routine operation
: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
MCS300P – Main Applications
: Waste Incineration – Raw gas- Scrubber control
: Cement plants – Kiln Inlet / Pre calciner- Process control
: Chemical Processes, e.g.- EDC/VC production- Isocyanate production- Nylon pre-products- Polyethylene production
: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
MCS300P – Waste Incineration
Raw Gas Measurement
: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
Raw Gas Measurement
: Measuring purpose- Control of scrubber (desulphurization process)- Injecting the proper amount of lime water [Ca(OH)2] or sodium
bicarbonate- ! Reducing operation cost !
: Measuring point- Directly after the incinerator - High Temperature and Heavy Dust Burden!
or- After the electrostatic precipitator, slower response, poorer control
: Measuring components- SO2 and HCl- H2O, CO, O2
MCS300P – Waste Incineration
: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013: Name (Date) 13
PMPM
CO, O2
CO, NO, O2, SO2
Flow
CO
CO, CO2, NO, SO2, O2
MCS300P – Cement Plants
: Process ControlPM, SO2, CO, CO2, NO2, NO, O2, H2O, HCl, Hg, NH3, HF, TOC, T, p, Flow
: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
MCS300P – Cement Plants
Process control
: Measuring purpose- Process control- Improving product quality
: Measuring points- At Kiln inlet / Pre calciner- Direct after secondary burner
: Measuring components- SO2, HCl, NO, NH3
- H2O, CO, CO2, O2
SCP Cement probe
: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
MCS300P Cabinet Design
: Cabinet set upIO Modules
Sender unit with operator panel
O2-Sensor (optional)
Cell / temperature controller
Heated pumpValvesReceiver unit
: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
MCS300P – User Benefits
- Applicable for various components and sample streams- Multi component system, max. 6 components- Low maintenance costs- Compact design
▪ Simple and fast installation- 2 Integrated temperature controllers
▪ Heating of process cell, sample gas line, pump …▪ Cost effective and convenient
- Adjustment filter wheel integrated (option)▪ For adjustment and drift checks without test gas▪ Saves money and time
- Certificates for use in Atex zone 1/2 as well as Class I Div 2 are in progress
: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
Process analysisTurnkey analysis container built to customer specifications
Process gas analysersintegrated in a container
Analysis container
Analysis cabinets within a container
17
: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
Raw Gas – single measurementGM700 TDL analyser
: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
Overview: GM700 cross-duct and probe versions
Model Component
All T, p
GM 700 - 1 O2
GM 700 - 2 HF
GM 700 - 3 HCl
GM 700 - 4 --
GM 700 - 5 NH3
GM 700 - 6 --
GM 700 - 7 --
GM 700 - 8 HCl, H2O
GM 700 - 9 NH3, H2O
: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
Basic data
: Basic technical data of GM700
- Measuring components O2, HF, HCl, NH3, (H2O), temperature, pressure
- Measuring Principle Tuneable Diode Laser Spectroscopy
- Measuring ranges (1m active path)
- O2 0…7 Vol% / 0…25Vol%- HF 0...5ppm / 0...2000ppm- HCl 0…20ppm / 0…3000ppm - NH3 0...25ppm / 0…4000ppm- H2O 0...50Vol% (GM700-8) , 0…3Vol% (GM700-9)
: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
100%
0%wavelength
detectorsignal
concentration ~ -log (Imeas/Ireference)
Laser-Scan Standard IR measurement technology
Gas 1
Gas 2
Tuneable Diode Laser SpectroscopyMeasuring Principle
: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
Ref Channel
Monitor ChannelMeasurement
Alignment Sight
GM 700 Optical Principle
: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
Application DeNox
: Measurement task:- NH3 slip control
- Temperature: 340 ... 420°C- Dust : 10 ... 20g/m3- NH3 concentration: typ. < 5ppm *)- SO2 concentration: up to 4000ppm
: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
(GMP probe shown)
Terminal
DAS
System Components
Cross-duct SR unitReflectorEvU control unitPurge supply
Probe version SR unitProbeEvU control unitPurge supply (GMP)
SR unit
SR unit Reflector
EvU unit
purge supply
: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
Benefits (I)
: Optimized application adaption by Cross-Duct and probe versions
: in-situ =
- without change of the gas composition
- short response time
- accurate and representative measurement
: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
Benefits (II)
: Highly stable system operation due to built-in reference cell and
analyzer self tests
: check cycle (HCl, NH3)
: Direct Spectroscopy = Drift- and calibration-free (= no test gas
required, free range selection)
: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
Applications (I): The gas analyzer GM700 is used in the following applications
- Aluminum Industry (HF, (EN 15267-3 suitability tested)
- Ceramics production (HF, (EN 15267-3 suitability tested)
- Nitric acid- and Fertilizer production (NH3)
- DeNOx monitoring (NH3)
- Waste Incineration (HCl, HF)
- Semiconductor production (HCl, HF)
- Cement plants (HCl, HF, NH3)
- Automotive (NH3)
: Thank you for your attention.