1. Ronald L. Baker Robert Peters Edul Chikhliwala EcoChem Analytics
Continuous Emission Monitors (CEMS) Advancements From Measuring HCl and Ammonia (NH3) to using Sensitive Moisture Measurements for Identifying Boiler Tube Leaks
Ronald L. Baker
Robert Peters
Edul Chikhliwala
EcoChem Analytics

2. Introduction & Overview
Stack Monitoring Systems are already at plants to measure “acid gases” (NOx & SO2) and often CO, O2 & CO2
Note: Stack moisture content, %H2O, typically measured as well
New or pending regulations in certain industries can require additional measurements:
HCl Hydrogen Chloride : another acid gas
NH3 Ammonia : related to ammonia/urea injection

3. Hot-Wet Sampling System

4. Gas Filter Correlation

5. Gas Filter Correlation

6. Single Beam Dual Wavelength

7. Single Beam Dual Wavelength

8. MC3 Analyzer Optical Path

9. System Components

10. MC3 Measurement Capability
Gas
Range Interval** CO
0-5 PPM to 0-10,000 PPM
Single MC3 analyzer can measure 8 gases
plus Oxygen
SO2
0-10 PPM to 0-1,000 PPM NO
0-5 PPM to PPM
NO2
0-5 PPM to PPM
CO2
0-1,000PPM to 0-40%
NH3
0-5 PPM to PPM
Dual ranges can be selected for same gas
HCl
0-10 PPM to PPM
H2O
0-2% to 0-50%
* All components at 185C or above; standard sample cell path 12 meters
** User can select appropriate range within the range interval
* Use of a short path cell can permit higher concentration ranges O2
0-25%
N2O
0-10 PPM to 0-1,500 PPM
CH4
0-10 PPM to 0-1,000 PPM

11. Moisture Measurements to Identify Boiler Tube Leaks
Since 2004, there have been 8 of these hot-wet analyzers installed at seven different waste coal fired facilities.
In addition to pollutant measurements of NOx, SO2, CO and diluents measurements of oxygen (O2) and carbon dioxide (CO2), these analyzers continuously monitor the concentration of moisture (H2O) in the flue gas stream.
This moisture measurement, similar to the other measurements, is updated every 7-10 seconds and has been shown to be effective in identifying and or verifying a boiler tube leak.
In the event of a tube leak, the increase in moisture can be fairly significant from the unit’s baseline moisture levels, ranging from a 1-3%+ increase. Therefore in a unit with a typical moisture level of 6.5%, a rather sudden increase to 8.5% moisture has confirmed boiler tube leaks.
Correlations improve after each event

12. EcoChem MC3 Systems – Waste Coal

13. HCl, Ammonia and Water Calibration
“Wet” Calibrations with the Hovacal unit
Hot-Wet
Vapor Mixture
Supply Unit
Evaporator
Mass
Flow
Meter
Mass
Flow
Controller
Temperature
Control
Pump
Liquid
Carrier Gas
Solution (pure water, NH3 or HCl)
Balance
(Optional)

14. MC3 Installations - HCl Wasatch Integrated Waste Mgmt
2 waste to energy units
Wheelabrator Falls – PA
Chemical & Waste Treatment Industry worldwide
- 15+ analyzers including Eli Lily & Company

15. MC3 Installations – NH3 TransCanada – Ocean State Power – RI
4 units on gas turbines with SCR
Wheelabrator Falls – PA
2 waste to energy units-evaluating de-NOx system
Fertilizer and Chemical Industry in USA
- 20 analyzers including Rentech Nitrogen, PCS, & CF Industries

16. HCl Dedicated CEMS
Major Utility in Texas
Installation near Dallas

17. Question and Answers
EcoChem Analytics