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


• 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


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)


—Air emission regulations


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


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


—What to expect from your CEMS vendor?


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


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


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


– 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


– 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)


—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


– 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?


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


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


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


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


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


—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


—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


—Emission registrationContinuous Emission Monitoring Data Acquisition System

Hg

—Set Up


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?


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


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

introduction abb netherlands - gain · single sampling point for all components single sampling...

Documents