CEMS Extractive

Key Components of a CEMS.

There are various operating methods and protocols for handling Continuous Emission Monitoring Systems (CEMS) at industrial sites, with different owners and national authorities implementing specific processes for sampling, conditioning, and assessing gases removed from flue effluent. While the exact components of a system may vary depending on the plant and its purpose, a typical CEMS generally includes the following elements:

• • A sample probe, which is the piece of equipment responsible for removing the sample from the flue gas stream.
  • A pump or other pneumatic plumbing equipment, which contains valves that regulate the extraction and distribution of the sample along the sample line. This regulation is normally conducted remotely by a programmable logic controller (PLC).
  • A sample line, along which the sample is transmitted to direct it to the analysing hardware.
  • An analyser (or analysers), which are capable of assessing the concentration of certain pollutants within the gas sample.
  • Filters to remove harmful contaminants like particulate matter (PM), which can damage the analyser equipment.
  • Conditioning equipment to remove water or other elements which could impact upon the capabilities of the analyser equipment and skew the results it produces.
  • calibration system, which is responsible for the injection of certain gases into the sample line in order to correctly calibrate the sample.
  • Data Acquisition and Handling System (DAHS), which is a centralised computer system that can collect, store and analyse the data, including the ability to perform calculations aimed at revealing the total mass emissions of a site over time.

Key Considerations:

Regulatory Compliance: Each component and flow scheme must meet specific regulatory requirements, which can vary by region. For example, Australian states adopting USEPA performance specifications will have stringent requirements for calibration and sampling.

Customization: The design and settings of the flow schemes can be customized based on customer needs, regulatory requirements, and process conditions. This flexibility ensures that the CEMS is optimized for both accuracy and efficiency.

Partnerships and Expertise: Working with experienced partners, such as PSG in Germany, can provide valuable insights and support for setting up and maintaining a CEMS that meets all necessary standards and functions effectively in your specific application.

If you have further questions about any specific component or need detailed guidance on setting up a CEMS, feel free to ask!

Which technology is right for my process?

FTIR / NDIR / In-Situ / Extractive / TDL

The CEM market is well-established, offering numerous technologies and options. However, selecting the right product for your process doesn’t have to be a daunting task! With our direct experience across various technologies and devices, we can help you navigate the jargon and find the best solution.

A practical approach for selecting equipment to meet regulatory requirements is to start with your permit.

When selecting instruments – a critical criteria is the minimum certified range of the device and its ratio to the process’s permitted daily ELV for component:

• For Incineration applications the certified range should be no more than 1.5 x the Daily ELV.
• For Combustion processes it should be no more than 2.5 x the Daily ELV.

You will likely notice that once this criterion is applied, the choice of equipment rapidly decreases!

FTIR

Continuous measurement provides better control of emissions than periodic measurement. Monitoring emissions continuously enables operators to react to changes in concentrations without any delay. Also, the measurement ranges can be changed easily and quickly (either extended or reduced) without any changes to the hardware thanks to the software and FTIR technology. These features are valuable to ensure future-proof operation in the face of changing emission limits.

Typical illustration set up for an Extractive system with either FTIR / NDIR or a mix.

The System offers the standard emissions monitoring package consisting of the following 16 gases: H₂O, CO₂, CO, N₂O, NO, NO₂, SO₂, HCl, HF, NH₃, CH₄, C₂H₆, C₃H₈, C₂H₄, C₆H₁₄ and CH₂O

The PSG Gas Sampling Probe product line is divided into two product versions:

The PSG Sample Gas probe BASIC, with its compact design, is an ideal solution for applications with low to medium dust levels in the Gas Sampling Process. The Gas Probes operate with holding temperatures of up to 200 ° C, a single stage back purging and calibration port are available standard.

The PSG Plus probe is the right gas probe for medium to high dust load. Thanks to the highly efficient two-stage back purging , low-maintenance operation is possible even in extreme applications. In the high-temperature version, holding temperatures of up to 300 ° C can be achieved within the Sampling Probe. Configurations are also possible for Gas Sampling in ATEX areas: each self-regulating heating element reaches holding temperatures of 90 ° C up to 180 ° C, thus making the Gas Probe processing efficiently even in dangerous ambient conditions.

Application

The controlled heated sample lines series PSG Basic Extruded are used for continuous extractive gas analysis. They serve primarily for the transport of the humid sample gas stream from the sample point to the analyzer house. The holding temperature of the line thereby has to be above water vapour resp. acid dew point of the sample gas. In this way uncontrolled condensation of water vapour on the way to the analyzer and therefore washing out of gas components in condensate is prevented.

CEMS In Situ

In-Situ Continuous Emissions Monitoring System

In-Situ CEM Analyzers:

These TDL gas analyzers are used to measure O₂, CO₂, CO, HCl, H₂S, Moisture, Ammonia (NH₃) and Methane (CH₄) in process gas streams.

1. Installation and Operation:

• • Flange Mounting: In-situ CEM analyzers are mounted directly to the emissions point on the stack, which eliminates the need for complex and maintenance-heavy sample handling components.

• • In-Situ Sample Cell: The sample cell is inserted into the stack where it directly measures the gas composition of the emissions stream. This direct measurement approach minimizes sample transport issues and potential contamination.

2. Measurement Technologies:

• • Infra-Red (IR) Analysis: IR analyzers detect gases based on their ability to absorb infrared light at specific wavelengths. This technology is effective for measuring gases such as CO2, CO, and hydrocarbons.
  • Ultra Violet (UV) Analysis: UV analyzers measure gases by detecting their absorption of ultraviolet light. This method is commonly used for gases like NOx (nitrogen oxides) and SO2 (sulfur dioxide).

3. Multi-Component Analysis:

• • Simultaneous Monitoring: In-situ CEM systems are capable of measuring multiple gas species at the same time. This multi-component capability allows for comprehensive emission profiling and ensures compliance with various regulatory requirements.
  • Water Vapour Measurement: These systems can also measure water vapor content in the emissions. The measurement of water vapor is crucial for reporting pollutant gases on a wet or dry basis, depending on local regulatory requirements.

4. Reporting Standards:

• • Wet vs. Dry Basis: Emission reports can be generated based on either the wet or dry basis of the pollutant gases. This flexibility ensures compliance with environmental regulations that may vary by region or specific emission permit requirements.

Advantages of In-Situ CEM Systems:

• • Reduced Maintenance: By eliminating the need for sample conditioning and transport systems, in-situ analyzers reduce maintenance needs and associated costs.
  • Real-Time Data: Direct measurement in the stack provides real-time data on emissions, which is crucial for operational control and compliance monitoring.
  • Enhanced Accuracy: Direct measurement reduces the risk of sample contamination and ensures more accurate readings compared to systems that rely on sample transport.
  • Cost-Effective: Lower maintenance and operational costs make in-situ systems a cost-effective choice over the long term, especially in complex or high-maintenance applications.

Applications:

• • Regulatory Compliance: In-situ CEM systems are often required for compliance with environmental regulations and standards, particularly for facilities with strict emission limits.
  • Process Optimization: Real-time data allows for better process control and optimization, helping facilities reduce emissions and improve efficiency.

In-situ CEM analyzers are a robust choice for emission monitoring, providing reliable, real-time data while minimizing maintenance and operational costs. If you have any specific questions about installing or operating these systems, or need guidance on compliance requirements, let me know!

Process analysers are ideal for a range of applications

• • Waste-to-energy plants
  • Combustion
  • Power plants
  • Gas turbines
  • Biomass
  • Glass industry
  • Cement plants
  • Pulp mills
  • DeNOx (SNCR, SCR)
  • Boilers & industrial furnaces
  • Process control

Why are they used?

Compliance to environmental regulations • Avoid regulatory penalties • Support process control • Optimize combustion to reduce fuel and lower emissions • Increase plant efficiency for extended lifetime of equipment • Decrease operating and maintenance costs of the plant • Improve productivity

Single sided In Situ analysers are also available.

TDL Process Adaptations

1. In Situ Measurement:
   • • Direct Integration: TDL spectrometers can be integrated directly into a process gas stream. This setup allows for real-time, continuous monitoring of gas concentrations without needing to remove samples from the process.
     • Advantages: Immediate feedback and high accuracy in monitoring gas composition and concentration, which is crucial for optimizing processes and ensuring safety.
2. Extractive Cell:
   • • Sampling and Analysis: In this configuration, a sample of the process gas is extracted and then analyzed in a dedicated cell. This method is useful when direct integration is not feasible or when more detailed analysis is required.
     • Advantages: Flexibility in settings and allows for more controlled measurement conditions.

3.  Environment Suitability:
   • • Fast or Slow Moving Gas Streams: TDL spectroscopy can be adapted for both high-velocity and low-velocity gas streams, making it versatile across different process conditions.
     • Dirty Gas Streams: The technology is capable of handling dirty gas streams, thanks to its design that can mitigate interference from particulates or contaminants.
     • Narrow Pipes: TDL systems can be installed in narrow pipes as small as DN50 (2 inches), making them suitable for compact or constrained spaces.
4. Folded-Path Spectroscopy:
   • • Principle: Folded-path TDL spectroscopy involves using a folded optical path within the measurement setup, which increases the effective path length of the laser beam through the gas. This technique enhances the sensitivity of the measurement.
     • No Receiver Alignment Needed: The design allows for accurate measurements without requiring precise alignment of a receiver, simplifying installation and operation.

Benefits of TDL Process Adaptations

• • Accuracy: Provides precise and reliable measurements of gas concentrations, crucial for process control and regulatory compliance.
  • Real-Time Monitoring: Enables continuous and immediate assessment of gas composition, facilitating rapid response to process changes.
  • Versatility: Adaptable to various conditions including fast or slow gas flows, dirty environments, and constrained spaces.
  • Reduced Maintenance: Minimal alignment requirements reduce the need for frequent adjustments and maintenance.

Applications

TDL spectroscopy is used in a wide range of industrial applications, including:

• • Chemical Processing: Monitoring reactants and by-products in chemical reactions.
  • Petrochemical Industry: Ensuring accurate control of combustion processes and emissions.
  • Environmental Monitoring: Measuring pollutant levels in emissions to comply with environmental regulations.
  • Glass and Cement Industries: Controlling and optimizing combustion processes and monitoring emissions.

Overall, TDL process adaptations offer a robust solution for precise and adaptable gas measurement in diverse industrial environments.

CEMS Dust, Flow, Temp

AQMS GROUP: Advanced In-Situ Multi-Gas Measurement System

The AQMS GROUP Advanced In-Situ Multi-Gas Measurement System is a cutting-edge, all-in-one compact solution for real-time multigas measurements. Leveraging proven Infrared (IR) analyzer technology, this system is engineered to measure up to 10 gases simultaneously

Superior Technology

AQMS GROUP’s instruments features a robust and reliable short extractive analyzer with an integrated permeation sample drying system, making it ideal for handling wet and corrosive samples. Utilizing the Infra-Red Gas Filter Correlation principle, the system monitors each selected gas in under 40 milliseconds. This advanced technology minimizes cross-sensitivity from other gases, ensuring precise and accurate measurements.

Additionally, the system tracks temperature, flow, and pressure through its integrated sample extraction probe, providing a comprehensive overview of sample conditions.

Reduced Costs

This in-situ multi-gas Continuous Emissions Monitoring (CEM) system incorporates sample drying and system conditioning within the unit itself, eliminating the need for external sample lines. Designed for straightforward installation, the IR analyzer offers flexible configuration options including single stack entry, on-stack, or close-coupled setups, resulting in lower installation and operational costs.

Compliance

Built to adhere to the Industrial Emissions Directive (IED), the AQMS GROUP system guarantees maximum operational availability and full compliance with QAL 1 of EN14181 standards.

CO, NOx, SO2, HCl, CH4, CO2 & H2O

The GCEM40 series is the latest generation of CODEL’s world renowned in-situ monitors. Our development, knowledge and practical experience have been utilised to produce this advanced technology gas analyser which gives complete flexibility of use on process or emissions applications whilst delivering superb accuracy and repeatability at a very competitive price.

Designed for use primarily on combustion processes, the GCEM40 series measures key pollutants such as CO, NO, NOx, SO2, CH4, CO2 and H2O using an infra-red spectroscopy to ensure that there is no cross sensitivity from other contaminants in the gas stream.

Software Data Acquisition System

What is a Data Acquisition and Handling System (DAHS)?

The primary functions of a DAHS are:

1. 1. Data Conversion: It takes analog signals from CEMS, which monitor DAHS is a system designed to collect, process, and manage data from emissions, and converts them into digital data.
   2. Data Storage: The digital data, which represents the levels of pollutants or substances measured, is stored for further analysis.
   3. Data Analysis: The system checks the measured levels against regulatory limits and performs necessary calculations.
   4. Reporting and Alerts: It generates regular reports and may issue alerts or warnings to relevant personnel or external systems if pollutant levels exceed permissible limits.

Components of a Data Acquisition System

1. 1. DAQ Hardware: This includes the physical components that interface with sensors and collect data, such as analog-to-digital converters.
   2. Sensors: These measure various physical quantities like concentration of pollutants, flow rates, etc.
   3. Signal Conditioning Hardware: This equipment processes signals from sensors to ensure they are accurate and compatible with DAQ systems. It may involve amplification, filtering, and other signal modifications.
   4. Computer Running DAHS/DAQ Software: This is the central unit where the software runs, processing the incoming data, performing calculations, and generating reports.

Pollutants or Substances Handled by a DAHS

A DAHS can manage data for a wide range of substances, including but not limited to:

• • Chemicals: Specific chemical compounds released into the environment.
  • Pollutants: Various pollutants such as CO2, NOx, SO2, particulates, etc.
  • Fuel Flows: Measurement of fuel consumption rates.
  • Air Flows: Data related to air movement and velocity.
  • Opacity: Measurement of light absorption by particulate matter in emissions.

Additional Information

For detailed information on Continuous Emissions Monitoring Systems (CEMS), which are integral to DAHS, you might refer to resources or documentation specific to these systems. CEMS are used to provide real-time data on the emissions from industrial processes, and the DAHS system ensures that this data is accurately processed and reported in compliance with environmental regulations.