: Latest Equipment Innovations for LCPD
Colin Blackmore/Mark Davidson SICK (UK) Ltd
AQE Conference March 2013
SICK process automation
Process
Emission
Industry overview
: SICK MAIHAK GmbH
Power
Waste
Cement
Pulp & paper
Metal & steel
Chemical
Petrochem &
refineries
Oil & gas
: SICK process automation
: C.Blackmore/M.Davidson AQE 2013
2
SICK process automation
Scopes
Emission
Process
Tunnel
Measuring devices and system
solutions for continuous
emission monitoring
Analyser for a variety of
process measurements
Measuring devices for tunnel
monitoring
•
Entire product range for all
requirements
•
Compact transmitters with
1 to 2 measuring components
•
•
In situ and extractive
measurement technologies
•
High-performance analysers
with up to 4 measuring
components
Rugged measuring devices
with 1 to 3 measuring
components
•
Measurement of air quality
and visibility
•
Early fire detection
•
Solutions for all industries and
legal regulations
: SICK MAIHAK GmbH
•
Multi-component analysers
> 4 measuring components
: SICK process automation
: C.Blackmore/M.Davidson AQE 2013
3
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
Air
preheater
Boiler
EP
FGD
Gas
preheater
FGD plant
Ammonia
DeNOx
Water
reactor
EP
Limestone
Slag
: SICK MAIHAK GmbH
Coal
Air
Ashes
: SICK process automation
gypsum
: C.Blackmore/M.Davidson AQE 2013
Application SCR DeNOx Plant
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
1
: SICK MAIHAK GmbH
: SICK process automation
: C.Blackmore/M.Davidson AQE 2013
Application SCR DeNOx Plant
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)
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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
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
SO2
NO
>>> DOAS
Differential
Optical
Absorption
Spectroscopy
NH3
NO2
Wave length
<-- 190 nm
: SICK MAIHAK GmbH
--> 400 nm
: 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
GM32
SCR 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
Stack
Power
CO NOx,, O2,
FLOW
Generator
Steam turbine
Cooling air
Steam
Combustion air
Gas turbine
Generator
Power
Heat recovery steam generator
Gas
Flow
Data Acquisition system Cem View or
MEAC2000
: SICK MAIHAK GmbH
: SICK process automation
: C.Blackmore/M.Davidson AQE 2013
Application: CEMS for CCPP
: Extractive Technology: In situ Technology
Flow
Gas
FLOWSIC100
PowerCEMS100
CO, NOx, O2,
option SO2, CO2
: 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
Control unit
BCU
: SICK MAIHAK GmbH
: SICK process automation
sample gas
cooler
: 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 stabilit
: With the UVRAS principle low ranges of NO, NO2, SO2 (0 - 25 ppm) can be accurately an
individually measured.
: Using the NDIR principle to measure CO in low ppm ranges (20 ppm) can be achieved. Ne
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 CC
: SICK MAIHAK GmbH
: SICK process automation
: C.Blackmore/M.Davidson AQE 2013
Emission monitoring
Application-specific fully configurable system
Central control unit
Connecting
additional networks
using standard
interfaces
Dust, volume flow (in situ)
High-grade
analyser modules
and components
All required gas components
(extractive)
(SO2, NO, NO2, NH3, HF, CO,
CO2, CH4, HCl,N2O, H2O...)
: SICK MAIHAK GmbH
: SICK process automation
: C.Blackmore/M.Davidson AQE 2013
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:
Thank you for your attention.