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Continuous Emissions Monitoring and Process Control

Internationally approved

Sulphuric Acid Production

The process control of a sulphuric acid plant needs good and reliable detection of gas phase SO2. To measure SO2 is a challenge due to the corrosive environment and high concentration of SO2.

Several places in the process needs to be monitored and to transport the sample gas is difficult. A large dy-namic range is needed as the SO2 concentration can vary between 15% volume and a few mg/m3.

Most systems installed need a lot of maintenance, sometimes as often as every day.

The Opsis DOAS system is different and provides sul-phuric acid plants with an accurate analyser that will op-erate with a minimum of maintenance.

A typical service interval with an Opsis system is 3 to 6 months. The Opsis DOAS system is a non-contact method, using an optical measurement path that oper-ates across a duct. The optical light is transported in an optical fibre to the analyser and one analyser can operate several paths.

Besides the measurements of SO2, additional gases such as SO3, H2O and O2 can be measured.

Return of InvestmentThe cost of investing in an Opsis DOAS system, to meas-ure SO2 and other gases, is small compared to the amount of money that can be saved by having better control of the process. The cost of the Opsis DOAS system is also small compared to the amount of money that are spent on maintaining old systems based on extractive techniques.

Please contact your Opsis supplier to discuss your particular system requirements, including the compounds youwish to monitor. Separate product and other industrial application sheets are available.Specifications subject to change without notice

Continuous Emissions Monitoring and Process Control in Sulphuric Acid Production

Test and ApprovalsThe Opsis System has been tested and approved by a number of internationally recognized institutes and au-thorities. The system meets the European directive for power plants and is approved by German TÜV, British MCERTS and U.S. EPA. Full details are available on re-quest.

Opsis Product PortfolioOpsis has a full product portfolio for measurements of gases in a sulphuric acid production plant. It includes systems for continuous emissions monitoring, process control as well as for air quality monitoring. The total solution also includes highly skilled service and support.

For further information, please visit www.opsis.se.

Analyser cabinet

Emitter

Receiver

Fibre optic cable

Stack

Power supply

An Opsis system layout for monitoring in a sulphuric acid production plant

AR600/AR620 AnalyserSO2 emission 0–5000 mg/m3 0–80 mg/m3 1 mg/m3 ±2 mg/m3 ±2% ±1% 100 m AR600/620SO2 process 0–100% Vol. — 0.1% Vol. ±0.2% Vol. ±2% ±1% 200 m AR600/620SO3(1) 0–1000 g/m3 — 0.3 g/m3 ±0.6 g/m3 ±2% ±1% 100 m AR600/620NO(2) 0–2000 mg/m3 0–150 mg/m3 1 mg/m3 ±2 mg/m3 ±2% ±1% 10 m AR600/620NO2 0–2000 mg/m3 0–20 mg/m3 1 mg/m3 ±2 mg/m3 ±2% ±1% 200 m AR600/620H2O 0–100% Vol. 0–30% Vol. 0.1% Vol. ±0.2% Vol. ±2% ±1% 100 m AR620Hg0 0–1000 μg/m3 0–150 mg/m3 3 μg/m3 ±6 μg/m3 ±2% ±1% 50 m AR600/620

AR650 AnalyserSO2 0–1000 g/m3 — 30 mg/m3 ±60 mg/m3 ±2% ±1% 10 m AR650SO3 0–1000 g/m3 — 30 mg/m3 ±60 mg/m3 ±2% ±1% 10 m AR650CO 0–10000 mg/m3 0–75 mg/m3 3 mg/m3 ±6 mg/m3 ±2% ±1% 10 m AR650H2O 0–100% Vol. 0–30% Vol. 0.1% Vol. ±0.2% Vol. ±2% ±1% 100 m AR650CO2 0–100% Vol. — 0.1% Vol. ±0.2% Vol. ±2% ±1% 50 m AR650

LD500 Laser diode gas analyser CO 0–100% Vol. — 0.1% Vol. ±0.2% Vol. ±2% ±1% 500 m* LD500CO2 0–100% Vol. — 0.1% Vol. ±0.2% Vol. ±2% ±1% 500 m* LD500H2O 0–100% Vol. — 0.1% Vol. ±0.2% Vol. ±2% ±1% 500 m* LD500H2S 0–100% Vol. — 0.1% Vol. ±0.2% Vol. ±2% ±1% 500 m* LD500O2 0–21% — 0.1% Vol. ±0.2% Vol. ±2% ±1% 500 m* LD500Temperature 0–1400°C — 10°C ±20°C ±2% ±1% 500 m* LD500

Compound Typical measurement range

Lowest TÜV approved measurement range

Min. detectable quantities (monitoring path 1 m, measurement time 30 sec.)

Zero drift (1 m path, max. per month)(3)

Span drift (per month, better than)

Linearity error (of mea-surement range, better than)

Max. length of fibre optic cable (when monitoring individual compounds)(4)

(1) Maximum SO2 concentration 500 mg/m3 × m(2) Maximum SO2 concentration 5 g/m3 × m(3) For AR650 the same values are valid as maximum zero drift per year. (4) When monitoring several compounds, the shortest fibre optic cable given by

the set of components (refer to product sheet P9) has to be used.

Besides the compounds above, the Opsis system monitors the following gases: hydrogen bromide (HBr), bromine (Br2), iodine (I2), hydrogen cyanide (HCN), hydrogen sulphide (H2S), phosgene (COCl2), and others.* Laser and communication cables.• Recommended monitoring path length: 1 to 5 m• After wet scrubbers or when the particulate concentration is high, the moni-toring path length may have to be reduced.

Performance Data (typical data which may vary depending on application)

Hardware requirement

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HeaterSulphur feed

Furnace

Heatexchanger

Mixing chamber

Heat exchanger

Heat exchanger

Contact unit

Stack

Conc. SO2 unit

SO3 absorptionunit

Dryingtower

Peroxidescrubber

Final absorptiontower

First absorptiontower

Cooler

SO2: 0–20% Vol.SO2: 0–20% Vol.SO2: 0–2% Vol.SO2: 0–2500 ppmNO: 0–500 ppmNO2: 0–100 ppmSO2: 0–1000 ppmSO2: 0–20% Vol.

1.2.3.4.5.

6.

Opsis Monitoring Paths

A schematic drawing of a sulphuric acid production plant including the SO2 and NOX measurement spots of the Opsis monitoring system

Why Opsis?

High-performance, cross-stack monitoring

Multi-gas and multi-path system

No sampling required, non-contact measurement system

Operates with a minimum of maintenance

Internationally approved

Hundreds of systems installed worldwide

Experienced and skilled service network

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Continuous Emissions Monitoringand Process Control

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Box 244SE-244 02 Furulund, SwedenTelephone Int +46 46 72 25 00Telefax Int +46 46 72 25 01E-mail info@opsis.seURL http://www.opsis.se

OPSIS AB