: 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
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Oil & gas
Power
Pro
cess
Em
issi
on
Cement Metal & steel
Chemical Petrochem &refineries
Pulp & paper
Waste
: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
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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: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
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)
: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
DeNOx Plant
Gas preheater FGD EP
Air preheater Boiler
Water
FGD plant
gypsum
Limestone
Ashes Slag Coal Air
Ammonia DeNOx
reactor EP
: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
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
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: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
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
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: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
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
: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
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
: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
GM32: The extended In-Situ solution
: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
>>> 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
: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
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
: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
GM32SCR De-NOx control
: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
CCGT plants - CEMs
: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
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,
: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
Application: CEMS for CCPP
: Extractive Technology : In situ Technology
PowerCEMS100
Gas
CO, NOx, O2, option SO2, CO2
FLOWSIC100
Flow
: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
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
: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
Best Solution: PowerCEMS 100
MAC800 compact system PowerCEMS 100 GMS 830 and 831 analyzer modules
sample gas cooler
Control unit
BCU
: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
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.
: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
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
: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
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
: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
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
: SICK MAIHAK GmbH : SICK process automation : C.Blackmore/M.Davidson AQE 2013
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.
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