Particulate and Emission Monitoring Solutions

technical services worldwide

for Regulatory Compliance and Process Control

Passionateabout

Particulate

EN 15267-3EN 15859 - Filter Dust Monitor - Filter Leak Monitor

Sira MC090152/00Sira MC110187/00Sira MC050066/05

About us

Regulatory Compliance:

Industrial processes installing and operating continuous monitoring instrumentation to meet and/or exceed national and international requirements including US EPA, UK MCERTS and German TÜV standards

• Measurementinmg/m3

• Monitoringtheperformanceoff ilter plant systems• Quantitative/indicativemonitoring

Corporate Responsibility:

Industrial processes monitoring emissions toprovidedata for theirowninternallydrivenenvironmentalprogramsand quality control procedures

• Improvedenvironmentalperformancethroughcorporategovernanceorenvironmentalprograms (e.g. ISO 14000)

• Instrumentsmeetthedemandforhighqualitymeasurementsimilartoanyprocessinstrumentwheredataisofvaluetotheorganisation

Process Improvement:

Industrial processes installing monitoring instruments to improve their processwithafinancialreturn

• Instrumentoutputisdirectlyusedtocontroltheprocess

• Typicalusesincludeimprovedpowderproduction,reductionofproductlossfromprocessparticlecollectiondevicesandreducedrunningcostsoffabricf ilters(e.gextendinglifeofbags)

PCME isaleadingspecialistinthedevelopment,manufactureandsupplyofcontinuousparticulateemissionmonitorsforindustrialprocesses.With instrumentsmonitoringover30,000emissionsourcesworldwideacrossabroadrangeof industries,PCME’sparticulatemonitoringsolutionsmeetstringentregulatoryrequirementswhichimproveenvironmentalperformanceandcontrol,increaseplanteffectivenessandassistinreducingcosts.

Headquartered inCambridgeshire,UK,withdistribution representingover40countriesworldwide,PCMEoperateacontinualdevelopmentprogrammetomaintaintheirpositionattheforefrontofadvancedparticulateemissionmonitoringsolutions.

ManyPCMEparticulatemonitoringsystemsarecertifiedbyTUVandMCERTStoEN15267-3withQAL1asdefinedbyEN14181.Othersystemsarecertifiedtothelatestperformancestandardspecifictofilterleak/filterparticulatemonitoring(mg/m3)asdefinedbyEN15859providingpeaceofmindthatthelatestregulatoryrequirementsaremet.

PCMEofferanunparalleledrangeofsensorandsystemtechnologies,withafocusonaddedvalue featuresdesigned toaddress thedifferingparticulateemissionmonitoringchallengesfaced by specific industries. These unique PCME features have been developed throughyearsofpracticalapplicationexperience,withongoingconsultationbetweenplantoperators,regulatorsandPCMEdrivingacontinuousdevelopmentprogramforthefurtheringofparticulatemonitoringtechnology.

ThePCMEQAL181WS(left)isdesignedtomeasureparticulateswherethefluegasisbelowdewpointorwherewaterdropletsarepresesnt.ThisproductmarksasignificantmilestoneinthatitisthefirstcompletesystemtobeTUVcertifiedtoEN15267-3withQAL1asdefinedbyEN14181withacertificationrangeof0-15mg/m3.Itutilisesadirectextractivecontinuousmonitoring approach with heating which overcomes the problem of interference fromcondensationandwaterdropletswhenusinganin-situparticulatemonitorafterwetcollectors.

Innovation and Product Development

PCME Provide Industry-Leading Solutions

Particulate Matter Continuous Monitoring System for wet stack applications

ThePCMESTACK160(right) issuitable formeasuringdustconcentrationsandmonitoringfilterfailureinmediumtolargediameter stacks (2 to 15m) on industrial and combustionprocesses.Itprovidesamoresensitiveandreliablealternativetotraditionalopacityinstruments.TheinstrumentisbasedonProScatterTMlaser-basedtechnologywhichmeasuresthelightscattered back from the particulate, without the need for aretroreflectorontheoppositesideofthestack. Back Scatter ProScatterTM

Particulate Monitoring System for large stacks

Particulate emission monitoring is a challenging technical field, not only because of the application-specific accuracy andperformanceofparticulateemissionmonitors,butalsoduetotheharshenvironmentsinwhichtheymustcontinuouslyoperate.Tomeetthesechallenges,PCMEproduceacomprehensiverangeofmonitoringsolutionstomeetthebroadneedsofparticulateemittingindustriesworldwideandtherequirementsofnationalandinternationalregulations.

Filter Performance Monitors continuously monitor and display particulate emissionsand indicate relative changes over time to provide valuable feedback on filter plantperformance (bagfilters, cyclone filters, dryers, scrubbers). In addition, the ability tolocatefaultyfiltermediabyroworcompartmentminimisestheneedtoreplacefiltrationmedia,reduceslabourrequirementsforfaultlocationandreducesprocessdowntime.This functionality can be combined with Particulate Measurement Systems andPCME’sdataloggingcontrolunits,andwhererequiredsystemsareavailablewithfullperformanceapprovals.

products

Particulate Measurement Systems

ParticulateMeasurement Systems provide continuousmeasurement of particulateemission concentrations which, for a defined range of application conditions,have the accuracy and consistency of response to be reliably calibrated againstisokinetic gravimetric test samples (standard reference method). PCME’s rangeof approved particulatemeasurement systems satisfy rigorous standards tomeetnational and international regulatory requirements. Instruments are also supplied fornon-regulatorymeasurementwithsimilarperformancetoapprovedinstruments.

Filter LeakMonitors, also known asBurst BagDetectors (Europe) andBag LeakDetectors (US), track changes in emissions from particulate arrestment plant andprovidea tool tominimiseemissionsandmonitor forarrestmentplantmalfunction(e.g. damaged filtration media). PCME’s range includes approved Filter LeakMonitorswherequalityassurancefeaturesarerequired–performancestandardsaresimilartoASTMstandardD7392-07forBagLeakDetectorsandthereforeofferMACTcompliantmonitoringsolutionsintheUSA.Instrumentsnotverifiedunderanapprovalschemeretainavarietyofqualityassuranceandfunctionalityoptions.

DustGrossFilterFailureDetectorstracksignificantincreasesinparticulateloadingstoindicatefailureinthearrestmentplant(e.g.grossbagfilterfailureorcycloneoverflow).GrossFilterFailureDetectoralarmstypicallyrequireimmediatereactivemaintenancetobetakenonthefilterplant,asthereisnopre-emptivewarningorearlyindicationoffilterdeterioration.

Filter Performance Monitors

Filter Leak Monitors

Dust Gross Filter Failure Detectors

industries

Monitoring Issues:

- Approvedandcertifiedsystems fordustconcentration,not simply colour

- Tolerancetoflyashwhich contaminates monitoring systems

- Lowmaintenanceneedsdueto limitedman-powertomaintain analysers and instruments

- Highlyabatedemissionsafter incinerationprocessesandtherefore minimumdetectionlevelconstraints

- EN-14181, incineration and combustionspecificstandards,WID (WasteIncinerationDirective) & LCPD (LargeCombustionPlantDirective)

- Tolerancetovibrationandhigh temperaturesandsuitabilityfor large stacks

- Dustanalysersareintegralbut specialistpartofemission CEM system

Monitoring Issues:

- Humidemissionsfrommineral drying and calcining plant

- ExtensiveuseofESP,Cyclone andbagfilterdustarrestment plant,allwhichcanfailcausing visibleemissions

- Environmentallysensitive emissionsfrommainkilnstack aswellasmultipleemission sourcesfrommills,coolersand

silos (IPPC, WID, LCPD)

- Tolerancetoabrasiveand contaminating dust

- Fugitivedustemissionsfrom storageandhandling

- Potential to emit large amounts ofemissionsduetolargesize offiltersystems

- Approvalsandregulatory compliance issue, US, European regulations under US EPA and IPPC

Emission Sources: - CoalFiredBoilers - RecoveryBoilers - OilandGasfiredboilers - Biomassboilers - Limestonedryscrubber - Activatedcarbondryscrubber - Municiplewasteincineration - Chemicalwastetreatment

Emission Sources:

- Kilns- Calciners- Rawmills- Clinker coolers- Cement mills- Silos/Materials Handling- Rotary ore dryers- Kettles- Boarddryingkilns- Mixingconveyors- Screening

COMBUSTION & INCINERATION MINERAL

TOBACCOMonitoring Issues:- Multipleemissionsourcesfrom primary and secondary processesEmission Sources:- Cutters & Dryers- ConveyingSystems- BlendersandMixers- CigaretteMakingMachines

ASBESTOSMonitoring Issues:- Verylowlevelsofparticulate- HighenvironmentalconcernsEmission Sources:- HighEfficiencyfilters(HEPA)

TIMBERMonitoring Issues:- Re-circulatingairfromarrestment plantintimberandwoodworkingindustrieswhilemeetingHealthand SafetydustexposurelevelsEmission Sources:- BoilerPlant- ExtractionSystemsonSaws, Planes,Machining&Sanding Processes

• LIME • CEMENT

• ROADSTONE • GYPSUM

• POWER PLANTS • INCINERATORS

• REFINERIES• PULP & PAPER

PCMEworkswiththeworld’smostdemandingindustrialcompaniesacrossabroadrangeofmanufacturing industriesprovidingsolutionswhichactuallyimproveenvironmentalperformanceandcontrol.

industries

Monitoring Issues:

- Humidemissionsfrommineral drying and calcining plant

- ExtensiveuseofESP,Cyclone andbagfilterdustarrestment plant,allwhichcanfailcausing visibleemissions

- Environmentallysensitive emissionsfrommainkilnstack aswellasmultipleemission sourcesfrommills,coolersand

silos (IPPC, WID, LCPD)

- Tolerancetoabrasiveand contaminating dust

- Fugitivedustemissionsfrom storageandhandling

- Potential to emit large amounts ofemissionsduetolargesize offiltersystems

- Approvalsandregulatory compliance issue, US, European regulations under US EPA and IPPC

PCMEworkswiththeworld’smostdemandingindustrialcompaniesacrossabroadrangeofmanufacturing industriesprovidingsolutionswhichactuallyimproveenvironmentalperformanceandcontrol.

Monitoring Issues:

- Tolerance to contaminating particulatewithhighcarbon, moisture and metal content

- Emission control is critical due to toxicnatureofsomeparticulates

- EXrequirementsfromBlast Furnaces

- Highlevelsofparticulateand largearrestmentplantfrom smelting,sinterandfurnace applications

- Lowlevelabatedemissions (typically <0.2 mg/m3) in non-ferrousandbattery industries

- Elevatedtemperaturesand abrasivedustscreateincreased maintenancechallenges

- Efficientcontrolandoperation ofmulti-compartmentbagfilters and ESP

Emission Sources: - Furnaces - Shotblastingprocess- Sand plant- Smeltingfurnaces- Converters- Lead refineries- Anodebakingovens- Coke plant- Calciners- Electrolytic reduction- Reverbertoryfurnaces- Steel casting- Blastfurnaces - Sinter plant

Emission Sources:

- Spray dryers- Agglomerators- Silos- Mills- Classifiers- Pelletizers- Fluidbedandrotarydryers- Dryers- Coolers- Materialshandling- Blenders- Process Reactors

METALS CHEMICAL AND FOOD

GALVANISINGMonitoring Issues:- Typicallyshort-termbatchprocessesEmission Sources:- GalvanisingBath

PHARMACEUTICALMonitoring Issues:- Humidemissionsfromdryingplant- Product loss

Emission Sources:- HighEfficiencyFilters(HEPA)- Spray Dryers- MaterialsHandling&Blending- VacuumTransfersystems&Silos

AUTOMOTIVEMonitoring Issues:- Oilaerosolsafterenginecompartmentmachiningoperation- PreventativeMaintenanceonfiltersEmission Sources:- Coalescentfilters - Paint Spray Extraction- CastingandShotblasting

• STEEL • FOUNDRY • BATTERY

• NON-FERROUS• ALUMINUM

• CARBON BLACK • PLASTICS • Ti02

• PIGMENTS

• SUGAR • STARCH• MILK POWDER

Monitoring Issues:

- Discriminatingbetweensteam and particulate in spray dryer stacksinfood,detergentand

chemicalindustry

- Tolerance to contamination due toinherentphysicalproperties ofcarbonblackandother chemicalpowders

- Explosivegaszonesinrefineries, paintoperationsandchemical processing

- ATEXdustzonesdueto potentiallyexplosiveareasin

starch,sugarandflourprocesses (problematicforopticalsystems)

- Extensiveuseofbagfiltersand cycloneswithmeasurement,

process optimisation and failuredetectionrequirements

- Digitalandanalogueinterface to existing instrumentation, plant control systems and LAN connections

The instrument interface is optimised for parallel use bymaintenance,processandenvironmentalpersonnel.Powerfulsingle and multi-sensor control units permit secure system configurationandaccess todata.Graphic trendand reviewscreens provide Bagfilterpulseandaverageemissionsconcurrently and local or PC configuration and reportingis fully supported by opendataarchitecture.

added value designs

Patented Insulated sensor technology (option) permitsinstrumentstooperatereliablyinhighhumiditystacksafterspraydriersandfluiddriers.ElectroDynamicTM measurement technologydiscriminateseffectivelybetweenparticulateandwatervapour.

ElectroDynamicTM instruments are tolerant to rod contamination since the charge induction is not restrictedtodirectcontactbetweenparticulateandthemeasurementsurface. DynamicOpacityTM instruments operate with noreduced accuracy even with the transmitter and receiveroptics 90% contaminated. The design of ProScatterTM

instrumentsensuresthatcriticalopticalcomponentsremainunaffectedbyanybuild-upofcontamination.

PCME’s particulate emissionmonitoring systems carry fullregulatory approvals including European CEM certification(QAL1 for EN 14181, EN 15267-3), German TA-LUFT,BlmSchV17,13and27,UKMCERTScertificationandmeettheperformancerequirementsforUS-EPAPS-1andPS-11.

Advanced ProbeContamination check

Dynamics of dust levels during bag cleaning. Cleaning Sequence marker pulses are fed to the system and displayed as red lines to aid in location of faulty filter rows

Robustautomaticself-checksareprovidedonallcomplianceinstruments,specificallyonPCME'sLightScatterinstruments.Thesechecksprovideanauditoftheinstrument'soperationwhile not changing the measurement principle to satisfyQAL 3 of EN-14181. The diagram below shows how themeasurement path remains constant while self-checks areperformedinaLightScatterinstrument.

PCMEprovideafullsuiteofPCsoftwareforemissionsreporting,instrumentconfigurationandprocessoptimisation.Softwareforthedownloading,displaying,analysisandreportgenerationofemissionsdatafromaPCMEemissioncontrolunitprovidesinstantaneousandhistoricalaccesstoemissionsdataforboth processandlegislativereportingpurposes.

• Real-timemode and short-term log for process control.Long-termlogforemissionreporting

• Powerfultrendviewswithzoomandpanfacilities• ReportingtosatisfyEN-14181(QAL3reporter)• Instrument overview, alarms, maintenance and failure

condition reports• Environmental reporting with data backup and system

redundancy• ‘Predict’softwareoptiontolocatefaultyfiltermediaand

reducemaintenanceonmulti-compartmentfilterhousesPatented insulated rod

Tolerance to Contamination Powerful User Interface

Humid Monitoring Conditions

Environmental and Process Reporting

Automatic Self-Checks

Approved, Accurate and Repeatable MeasurementsSensoroptionsandmodulesareavailable formonitoring inchallengingindustrialconditionsincluding:

•Elevatedpressureandtemperatureapplications•Acidattackprotection(combustionoffuelswithhighsulphurcontent)•Elevatedtemperatureacidattackprotection(asabovewithhighertemperaturerating)•Highhumidityapplications(processandspraydriers)•Airpurgedsensor(conductivedustandhighdust applications) •Explosivedustandgaszones(ATEXandIEX)

Rugged Sensor Options

ElectroDynamicTM rod contaminated with carbon black

Measurment volume of ProScatterTM - Forward Scatter instrument

technologies

ElectroDynamicTM

Principle of OperationProprietarytechniquebasedonachargeinductionprinciplederivedfromparticle interaction is not restricted to directcontactwiththeprobeinsertedintoastackorduct.Theinstrumentoutputisananalysisofthisfrequencyresponse and in appropriate applications isafunctionoftheconcentrationofparticulate

Applicability• Bagfilters,Cyclones,Humidair streams* * using patented insulated sensor

Dust Concentration• 0.01mg/m3 to 10,000mg/m3 (productspecific)

Certification Range• 0–15mg/m3 (MCERTS/TUV)

Unique Features• Unaffectedbycontaminationof probe• Uniquesolutionfordryers&humid gas streams • Optimisedtotoleratechangein velocityof8-18m/s(unlike Triboelectricsystems)• ZeroandSpanChecks• PatentedInsulatedSensorforhumid applications• PatentedProbeContamination check• Velocity Insensitivity: ElectroDynamicTM instruments maintaincalibrationunderchangingvelocityconditionsof8–18m/s.(IndependentlyverifiedbyGerman TÜV)

ProScatterTM

Principle of Operation • ForwardScatter-Coneof scatteredlightfromparticles withinthemeasurementvolume ofthesensorprobeiscollectedand measured•BackScatter-measurestheamountoflightscatteredbackfromparticlesinthestackilluminatedbya modulated laser Applicability • Incineratorswithdryscrubbers, cementkilns,powerplant(oil,gas andcoalfired) Dust Concentration • 0.1to1000mg/m3-ForwardScatter• 1to500mg/m3-BackScatter Certification Range •0-15mg/m3(QAL1)-ForwardScatter

Unique Features• Extendedtemperaturerange (nofibreoptics)• Detectorpositionunchangedinself- checkmode• Self-checkstomeetPS-11andQAL 3 (EN-14181)• Extractivesystemavailbaleforwet stacksbelowdewpointorwith waterdropletspresentForwardScatter:• Conemeasurementincreases particleinteractionvolumeBackScatter:• Convenientlymountedononeside ofthestackandrequiresno lightabsorberorbeamdumponthe oppositesideofthestack• Idealformeasuringlowdustlevels in large stacks

Transmissometry

Principle of Operation • OpacityTM-measurementbasedonchangeinmeasuredlightintensity•DynamicOpacityTM - ratiometric measurementbasedonlightintensityvariation

Applicability • Bagfilters,ElectrostaticPrecipitators, Cyclones,BoilerStacks

Dust Concentration • 10mg/m3 to 10,000mg/m3

(minimumdetectionlimitisapplicationspecific)

Certification Range • 0–150mg/m3 (MCERTS/TUV)• 0–30mg/m3 (TUV)

Unique Features• Ratiometricmeasurementpermits accuratemeasurementwhenlens contaminated up to 90% • Zeroandspanchecksoncompliance instruments• Selectabledustconcentrationand/or opacity outputs• Lightintensity,upscalechecks• Optionalauditunit(modelspecific)• Blowersystemsnotrequiredsince airpurgeissufficient

PCMEhaveacomprehensiverangeofparticulatemonitoringtechnologiestoensurethatonlytherighttechniqueisusedinaparticularapplication.Interferenceandcross-sensitiviesareminimisedbyselectionofthemostappropriatetechnology.

Back Scatter technology schematic

0 0.01 0.1 1.0 10 100+ 1000 10,000

5

10

15

Dust Concentration (mg/m3)

Stac

k D

iam

eter

(m)

ProScatterTM - Forward

ElectroDynamicTM

DynamicOpacityTM

OpacityTM

ProScatterTM - Back

This graph is intended to be representative of each technology. The actual capability is application dependent.

technical services worldwide PCME offerindustryleadingexpertisetocustomersandpartnersthroughacomprehensiverangeoftechnicalsupportservices,trainingpackagesanda‘knowledgetransfer’approach.Ouraimistoprovideexpertadviceandsupporttoaidyouinmeetingyourspecificparticulatemonitoringchallenges,frominitialconsultationandproductselectionthroughtolife-cyclesupportservicesandtailoredmaintenanceprograms.ThedemandsofmeetingEnvironmentalregulatorycompliance,processcontrolandoptimisation,plus corporate social responsibility needs, each present unique demands on particulate monitoring. Our Technical SupportServicesTeambringexperiencefromawiderangeofindustrysectorsandprocessapplications,thusensuringthatsystemsareset-up,operatedandmaintainedtomaximiseperformanceandfunctionalityfortheirintendedpurpose.PCME’srangeofTechnicalServicesalsoenableEnvironmentAgencyregulatedprocessesthataresubjecttotheOperatorMonitoringAssessment(OMA)schemetomaintainorimprovetheirscoringthroughhavingformalandservicemaintenancecontractstoensurethatcalibrationandmaintenanceiscarriedoutatthecorrecttime.OurservicepackagesalsohelpensurePartA2andPartBprocessesmettheirpermitrequirementswithregardtomaintainingtheirmonitoringsystems.

PCME’sservicecapabilityextendsthroughouttheworldandhasproventoproviderobust,responsiveservicestoourglobalcustomerbase.Weknowtheimportancetoourcustomersofhavinginstrumentsservicedattheirsitestoreducedowntimeandincreaseinstrumentavailability.World-wideservicepartnershaveteamsofserviceengineerswhoaretrainedbyPCMEtoprovideon-sitesupport.IntheUK,anetworkoffieldserviceengineersprovideson-sitenationalcoverage.

Preventative maintenance, extended warranty, rapid breakdown response andcalibrationservicesareallcoveredbyarangeofservicecontractstomeetregulatoryandprocessspecificsupportrequirements.IntheUK,arangeofcontractshelpoperators achievea highOMA (OperatorMonitoringAssesement) score for theirmonitoringsystemsandworldwidePCMEsupportsitsdistributionpartnerstoprovidesimilarhighlevelfieldandfactoryservices.

ManyofPCME’sinstrumentsincludeautomaticself-checkstoprovidewarningoftheneedforanyinstrumentrepairorservice.Inthecaseofinstrumentbreakdownournetworkoffieldserviceengineersarefullytrainedtocarryoutinstrumentfaultanalysisandrepaironsite.FactoryrepairservicesareavailablefromtheUKheadquartersinStIves,Cambs.

PCMEunderstandsthatacalibrationisnotsimplyanIso-kinetictest.Documentedandtraceablecalibrationprocedurescaptureinstrumentperformanceandconfiguration.Calibrations are provided using a range of National and International samplingstandards(eg.EN13284-1andBSISO9096)viaasubcontractednetworkofapprovedsamplingpersonnel.IntheUK,samplingpersonnelareMCERTSapproved.

PCME provides regular on-site and factory service training for plant personnel tosupporttheirmonitoringsystems.Inaddition,PCMEorganisesTrainingCoursestoimproveknowledgeandunderstandingofinstrumentservicerequirements,legislativeissues,thefeaturesandperformanceofmonitoringsystemsandtheoptimiseduseofemissionsanalysisandreportingsoftware.

Worldwide on-site support

Service Contracts

Breakdown Service

Calibration Services

Training

PCME LtdClearview Building

60 Edison RoadSt Ives Cambs UK

PE27 3GH

Tel: +44 (0)1480 468200Fax: +44 (0)1480 463400

E-mail: contact@pcme.comwww.pcme.com

Contact your national or area sales and service office

PCMEhaveglobal service centrestocoverrepairsinNorthandSouthAmerica,Europe,Australasia,AsiaandAfrica.Pleaseseeourwebsiteforfurtherdetails.