Introduction ABB Netherlands - Gain · Single sampling point for all components Single sampling...
Transcript of Introduction ABB Netherlands - Gain · Single sampling point for all components Single sampling...
—Introduction ABB Netherlands
28 September 2018 Slide 1
Mohamed TajjiouSales Specialist M&AE-mail: [email protected]: 06 1521 5918
Ruud WesselsAnalytical Project managerE-mail: [email protected]: 06 5354 2328
—Agenda
28 September 2018 Slide 2
• ABB Benelux organization• Continuous Gas analyzers portfolio• CEMS application
—ABB Benelux Organization
Country Managing Director BeneluxJ. Pauwels ^
Legal & IntegrityN. Ghafoerkhan ^
Van Lien, Enclosures,EV Charging
Spirit IT
Head ofDivision
LocalBusiness
Units
Divisions
^ Member of the Benelux Management Team• Finance including OPEX/Quality
Power Generation &Water
Turbocharging
Marine & Ports
CT, OGC and PI
Industrial Automation
G. Dekkers^
Measurement &Analytics
CorporateFunctions
Power Quality
Power Grids
S. Bogemans^
High VoltageProducts
Transformers
Grid Integration
Grid Automation
Production
ElectrificationProducts
J. van den Bent^
Protection &Connection
ElectrificationSolutions
Medium VoltageProducts
Building Products
InstallationProducts
Sales CouncilP. Van Den
Heede
Robotics & Motion
S. Seurinck^
Drives
Robotics
Motors &Generators
Power & ElectricVehicle
Infrastructure
CustomerExperienceV. Wendrix^
Communications
V. Van Asbroeck
Service &Logistics
V. Wendrix ^
Health, Safety,Environment
B. Maes
HRA. Klop ^
FinanceS. Husi ^
—Continuous Gas Analyzers (CGA)Most complete portfolio in the industry
28 September 2018 Slide 4
AO2000High-end product line
EL3000Entry level product line
EL3060Ex-d product line
Extractive
LS4000 / LS25Tunable diode laser
AZ SeriesZirconia O2/COe
In-situ
ACF5000Hot/wet extractive
ACXCold/dry extractive
Easy SystemCold/dry extractive
Standard Systems
AnalyzeIT ExplorerAsset management
CEM-DASCEMS Data Acquisition
Software
—MEASUREMENT & ANALYTICS
Continuous Emission Monitoring Systems (CEMS)Exceeding your expectations
Hg
—Products of combustion processes
Watervapor(H2O)
Hydrogenfluoride
(HF)
Mercury(Hg)
Hydrogenchloride
(HCl)
Particulates(dust)
Carbonoxides
(CO + CO2)
Nitrogenoxides
(NO + NO2)
Sulphuroxides
(SO2 + SO3)
28 September 2018 Slide 6
—Air emission regulations
28 September 2018 Slide 7
Overview
National Directives
EU LegislationEC Directives & Standards
2010/75/EU (IED)EN14181 & EN15267
USA & Canada LegislationEPA Regulations
Clean Air ActRules CSAPR, NAAQS, NESHAP
40 CFR Part 60, 63, 75
Asia & other regionsDifferent standards
Most of regulationsfollow EU and/or USA
legislationCountry legislation
Regional & local legislation
Kyoto Protocol
Country legislation
Regional & local legislation
International Treaties / Agreements
Sofia Protocol Paris Agreement Asia Pacific Partnership
—
How do Ichoose?
First time buyer
28 September 2018 Slide 8
Typical thought process
What’s in itfor me?
Confusingregulations!?!
I just want thisto go away!
—
Non-compliance muchmore expensive;fines, corrective
actions etc.
Eventual costs will bemuch higher;
due to low accuracy,poor reliability
Regulations onlygetting stricter,
someone will checkat some point
Not there when youmost need help;
extended downtime,expensive repair
Higher lifecycle coststhan expected;
calibration, partsreplacement etc.
Risks
3. Supplier saysthey meet allregulationsTrust their
word?
1. No processbenefit
Buy cheapestavailable?
2. Authoritiesdon’t enforce
regulationsInstall and
forget?
5. Supplier saysCEMS will never fail
Trust theirword?
4. Supplier saysall CEMS require
same maintenanceTrust their
word?
First time buyerCommon pitfalls
—
Choose your supplier carefully – pay attention to certifications, references, capabilities, commitments
Risks Risks Risks Risks
28 September 2018 Slide 9
—What to expect from your CEMS vendor?
28 September 2018 Slide 10
Certifications, references, capabilities, commitments
Uncertainty
How low?– measuring ranges
– cross sensitivities
– zero/span drift
– external influences
Availability
How high?– inspection
– calibration
– maintenance
– breakdown
Maintenance
How much?– per day
– per week
– per month
– per year
Service
How fast?– by phone/remote
– fault diagnosis
– parts delivery
– to site
Choose your supplier carefully – get it right first time, or at least second time
—Types of CEMS
28 September 2018 Slide 11
Overview
Extractive In-situ Parameter
CEMS
Source level Dilution Path Point Parametersurrogate Predictive
Emprical
First principle
Wet
Dry
Out-of-stack
In-stack
Dual pass
Single pass
—Installation methods
28 September 2018 Slide 12
In-situ (Path)
Extractive
In-Situ (Point)
PEMS
—
In-situ (Path)
Extractive
In-Situ (Point)
In-situ (Path)
Extractive
In-Situ (Point)
In-situ method
28 September 2018 Slide 13
– Direct installation into the process
– Direct detection of changing concentrations
– No delay in measurement (small T90 time)
Advantages
– Detector exposed directly to temperature and pressure
– No or less protection to dust and harsh processes
– Often only one or two components can be measured
– Difficult installation, e.g. at the top of a stack etc.
– Necessary to dis-mount for maintenance and repairs
Disadvantages
—
In-situ (Path)
Extractive
In-Situ (Point)
Extractive method
28 September 2018 Slide 14
– Sampling automated, no manual effort
– Multi component measurement possible
– Easy maintenance of the analyzers
– Easy calibration
Advantages
– Additional effort for sampling and conditioning
– Dispose of the sample gas
– Leakage in sample system (misreading)
– Sometimes long response times (T90)
Disadvantages
—Dilution extractive method
– Not necessary to remove H2O
– Analyzers only exposed to trace pollutants
– Eliminates problems with acid formation (> 500 ppm)
Advantages
– Dry dilution air, free from contaminants, must becontinuously supplied
– CO2 measurement required to verify dilution ratio
– Dilution ratio must be carefully set based on analyzer spanand sample dew point
– Stack temperature, pressure and molecular weight haveunfavorable impact
– Single component analyzers necessary which adds cost
Disadvantages
Dilution gas
Vacuum gauge
Sample gas(diluted)
Sample gas(undiluted)
28 September 2018 Slide 15
—Predictive method
– Minimal amount of hardware required
– Reduced maintenance and spare parts
– Overall lower cost of ownership compared to CEMS
– Can help to increase availability of CEMS up to 99.5%
Advantages
28 September 2018 Slide 16
– Only suitable for stable and consistent fuel sources
– Not suitable for waste incineration or cement production
– Requires some time and effort to initially establish the model
– Temporary CEMS may be required to collect emission data
Disadvantages
—How to make the right choice?
28 September 2018 Slide 17
Simplified guide
Consideration Criteria Recommendation Justification
Number ofcomponents
≤ 2 (incl. O2)3-5≥ 6
Extractive systemExtractive systemHot/wet extractive system
Single sampling point for all componentsSingle sampling point for all componentsMost cost effective solution
Measuringcomponents
CO, NOx, SO2, CO2O2THCHCl, HF, NH3, CH2O
Extractive systemExtractive systemFID analyzerHot/wet extractive system
Single sampling point for all componentsSeparate device necessary, easily integratedOnly approved method currentlyMost cost effective and reliable solution
Componentconcentrations
≤ 500ppm Source level extractive system Most cost effective solution
Type offuel source
Coal / OilGasWaste
Extractive systemSource level extractive / PEMSHot/wet extractive system
3-5 components likely, most cost effectiveLow and stable emissions, most cost effectiveMany components required, most cost effective
—Gas analyzer overview
28 September 2018 Slide 18
Gaschromatography
Chemicalreactions
Flameionization
Massspectroscopy
Para-magnetism
Thermalconductivity
Opticalspectroscopy
Fluorescencespectroscopy
Chemiluminescencespectroscopy
Emissionspectroscopy
Measuring principles
Zirconia
Laserabsorption
spectroscopy
UltravioletPhotometry
InfraredPhotometry
Absorptionspectroscopy
Photometry
Opticalspectroscopy
Absorptionspectroscopy
PhotometryLaser
absorptionspectroscopy
UltravioletPhotometry
InfraredPhotometry
Gaschromatography
Flameionization
Para-magnetism
Thermalconductivity Zirconia
—
Segment CSegment B
Segment A
CEMS market segments
28 September 2018 Slide 19
Price
Segment A (entry level)– Cold/dry extractive type– ≤ 5 measuring
components– 15 – 40 k€/system– Boilers, Biogas, Crematoria
Capabilities
Segment B (mid-range)– Cold/dry extractive type– ≤ 6 measuring
components– 30 – 80 k€/system– Power, Cement (no waste fuel),
Iron & Steel, Pulp & Paper, etc.
Segment C (high-end)– Hot/wet extractive type– > 6 measuring
components (typically)– 80 – 150 k€/system– Incinerators, Cement (waste fuel)
—Sample handling system
28 September 2018 Slide 20
Off-gas(treatment)Analyzer
Sampleconditioning
(Cooler)
Sampletransport
(Pump)
Sampling(Probe, Filter)
Process, stack,pipes, tanks, …
Sample Handling System (SHS)Signal
processingand reading
Sample Point
Control and maintain of function
—Hot/wet sample handling system
28 September 2018 Slide 21
Heating the complete system is not as simple as it sounds!
Exhaust gas isunconditioned!
Off-gas(treatment)Analyzer
Sampleconditioning
(Filtration/Flow)
Sampletransport
(Pump)
Sampling(Probe, Filter)
Process, stack,pipes, tanks, …
Sample Handling System (SHS)Signal
processingand reading
Sample Point
Control and maintain of function
All wetted components must be heatedand insulated to avoid cold spots!
—Keys to designing a hot/wet system
Ensure temp.maintained above180°C at all times
Limit number ofconnections betweensystem components
Minimize distancesbetween components
Reduce deteriorationfrom heating (e.g.
diaphragms, o-rings)
Protect the system incase the temp. is not
maintained
28 September 2018 Slide 22
—FTIR measuring principleSample of classic single moving mirror (Michelson Interferometer)
+Interferogram
FourierTransform
Spectruml [ m m]x
A Fixed mirror
B Movingmirror
Beamsplitter
IR detector
Distance [ x ]
10004000 3000 2000
Reference spectrum
3000 2000 10004000
Sample spectrum
=
IR source
28 September 2018 Slide 23
—Additional equipmentCompleting the hardware offering
Principle
– Sensor + transmitter
Solution
– ABB 266 series
Principle
– Sensor + transmitter
Solution
– ABB TSx/TTx series
Principle
– Differential pressure
– Ultrasonic
Solution
– ABB StackFlowMaster
– Durag D-FL 220
Principle
– Opacity
– Light scatter
Solution
– Durag D-R 290,D-R 808, D-R 320
Principle
– Atomic absorption
– Atomic fluorescence
Solution
– Durag HM-1400 TRX
Pressure Temperature Flow Particulate Mercury
Hg
28 September 2018 Slide 24
—Emission registrationContinuous Emission Monitoring Data Acquisition System
Hg
—Set Up
28 September 2018 Slide 26
Typical configurations
Stack
Dustmonitor
P, T, V
mA signals,digital contacts
Field Level
EthernetTCP/IP
Plant linestatus signals
Webbrowser
ModbusTCP/IP
Stack
Dustmonitor
P, T, V
DAHSI/O‘s
mA signals,digital contacts
Field Level
Switch
CGAcabinet
ModbusTCP/IP
Office LevelRegistration
Webbrowser
DataAcquisition
Unit
EthernetTCP/IP
ModbusTCP/IP
DCS
Office LevelCommonSimplest
—PEMSPredictive Emission Monitoring System
—What is predictive emission monitoring?
28 September 2018 Slide 28
Utilizing historic emission data and/or process measurements to accurately predict gas emissions
Fuel composition
Flow
Pressure
Temperature
Historicemission
data
Empiricalmodel
Ideally suited toconsistent fuel sources
Subject to CEMSperformance standards
—PEMS
28 September 2018 Slide 29
Key benefits
– Cost-effective alternative to traditional hardware CEMS• Lifecycle costs can be reduced by around 50%
– Independent from the automation system supplier• Easy and seamless integration with existing infrastructure
through standard communication protocols
– Very compact footprint:• Typically installed in standard Server PC, interfacing with
process control system without additional devices
– Minimal maintenance required:• Only a periodic recalibration useful for extending covered
operating conditions
• No consumables and spare parts needed → no warehouse
– Insight on process: identification of potential abnormalconditions and pre-evaluation of the root cause foremission upsets