1. Latest Equipment Innovations for LCPD
Colin Blackmore/Mark Davidson SICK (UK) Ltd
AQE Conference March 2013

2. SICK process automation Industry overview
Emission
Power
Waste
Cement
Pulp & paper
Metal & steel
Chemical
Petrochem &
refineries
Oil & gas

3. SICK process automation Scopes
Emission
Analyser for a variety of process measurements
Process
Compact transmitters with 1 to 2 measuring components
High-performance analysers with up to 4 measuring components
Multi-component analysers > 4 measuring components
Measuring devices for tunnel monitoring
Tunnel
Rugged measuring devices with 1 to 3 measuring components
Measurement of air quality and visibility
Early fire detection
Measuring devices and system solutions for continuous emission monitoring
Entire product range for all requirements
In situ and extractive measurement technologies
Solutions for all industries and legal regulations 3

4. Equipment for LCPD Process gas analysers
DeNOx process monitoring and control equipment
Continuous Emission Monitors - General Gas Analyser systems for Coal, Gas, Oil Power Stations
CCGT Plant and measurement of low levels of NOx
Mercury monitoring in Coal-fired Power Stations (separate Workshop presentation)

5. DeNOx Plant Gas preheater FGD EP Air preheater Boiler Water FGD plant
gypsum
Limestone
Ashes
Slag
Coal
Air
Ammonia
DeNOx
reactor EP

6. Application SCR DeNOx Plant
Why do we want to measure?
With the help of a catalyst, NO and NH3 react to N2 and water:
4 NO NH3 + O2  4 N H2O
NO measurement is important for the process control:
a) raw gas before catalyst : to calculate the NH3 injection rate
based on the “NO load”
b) check catalyst efficiency and NH3-trim 1

7. Application SCR DeNOx Plant
Technical Data:
Measuring Range:
before SCR: up to 1,500ppm NO depending on burner technology
after SCR : up to 100ppm NO depending on local regulation
gas temperature: °C
high dust : typically 15g/m3
duct size: typically 5m ( >6m) 1

8. Extractive Technology Challenges
Multiple Sample Probes with graded entry holes to try and balance the sample flow across large ducts and ensure accurate measurements
Standard extractive CEM system with Filtration, Cooling, Sample Switching
Problems
- very high dust burden
- high maintenance load on Sample Systems
- unreliable systems

10. In-situ Technology Challenges
Cross duct not practical due to high Dust Burden, extinction of signal in large ducts
High temperature application
Sick Solution – extract sample and measure with small path length
Orientate probe so as to avoid large particles being captured
If 15m/sec flow achieved then remaining dust stays in suspension
Dust shows as general extinction, which can be calibrated out

15. GM32: The extended In-Situ solution

16. Differential Optical Absorption Spectroscopy
GM32 - optimized measuring value evaluation Absorption curves of SO2, NO, NO2 and NH3
Evaluation principle DOAS with sophisticated algorithms
No influence of dust, droplets, humidity and other gases
In-situ >>> delay free
High and stable accuracy for high and low measuring ranges
Wave length
Extinction
SO2 NO
NH3
NO2
< nm
--> 400 nm
>>> DOAS
Differential Optical Absorption Spectroscopy

17. GM32 - Optical System - Control Cycle
Advantages:
Automatic self test Basic,Pro and upon request
Check of zero Basic,Pro and span Pro for each component.
No test gases required.
Compliance to EN 14181, EN
QAL3 zero & span values Pro
TÜV approval Pro
Interval adjustable Basic,Pro
Pro Version with filter wheel
Basic version without ~
no difference in quality of measurement

18. GM32 SCR De-NOx control

19. CCGT plants - CEMs

20. Heat recovery steam generator
Power
Stack
CO NOx,, O2,
FLOW
Generator
Steam turbine
Cooling air
Steam
Combustion air
Gas turbine
Generator
Power
Heat recovery steam generator
Gas
Flow
Data Acquisition system Cem View or MEAC2000
: SICK MAIHAK GmbH Power_CEMS forCCPP_en_2012_09 5

21. Application: CEMS for CCPP
: Extractive Technology : In situ Technology
Flow
Gas
FLOWSIC100
PowerCEMS100
CO, NOx, O2, option SO2, CO2
: SICK MAIHAK GmbH Power_CEMS forCCPP_en_2012_09 5

22. Minimum Requirements / Recommendations
: Gas components
Nitrogen monoxide (NO) + Nitrogen dioxide (NO2) = “NOx as NO2”
IR not low enough ranges for NO
Carbon monoxide (CO)
- Oxygen (O2), correction to reference conditions
: Option
- Sulfur dioxide (SO2), Carbon dioxide (CO2)
: Flow measurement
: Data acquisition system according to the EN or US EPA requirements
: SICK MAIHAK GmbH Power_CEMS forCCPP_en_2012_09 5

23. Best Solution: PowerCEMS 100
MAC800 compact system PowerCEMS 100
GMS 830 and 831 analyzer modules
Control unit BCU
sample gas cooler
: SICK MAIHAK GmbH Power_CEMS forCCPP_en_2012_09 : Name (Date) 6

24. PowerCEMS 100
> Certified according to EN and EN to be used as AMS for CCPP
> Compliant to EPA Part 60 and Part 75 CEMS requirements for gas fired power plants > Single central operating unit (BCU) for easy operation
> No NOx converter for better measurement accuracy and lower cost of consumables
> Low level CO monitoring done by field proven UNOR best accuracy of any NDIR on the market.
> Compact, suitable for wall mounting
> Interface to DAS or DCS via Modbus or OPC or hard wire, adaptable to customer’s requirements.
: SICK MAIHAK GmbH Power_CEMS forCCPP_en_2012_09 : Name (Date) 8

25. Best Solution: Flowsic100
> Flue gas temperatures up to 450°C
> High accuracy even at gas velocities near zero
> Corrosion resistant Titanium transducers as standard > Representative measurement using cross-stack version
: SICK MAIHAK GmbH Power_CEMS forCCPP_en_2012_09 : Name (Date) 8

26. Why is DEFOR better than Chemiluminescence ?
> Continuous individual measurement of up to 3 components NO, NO2 and SO2
> No interference from background gases (H20 and CO2 show no absorption in the UV range)
> Adjustment unit for calibration of DEFOR without using test gas
> No Converter, No Ozone = less trouble
: SICK MAIHAK GmbH Power_CEMS forCCPP_en_2012_09 11

27. : User-friendly analyzer system
GMS800 Advantages
: No need to use a NOx converter, change converter cartridges
: User-friendly analyzer system
: Designed for lower maintenance: simple single-point linearization, excellent thermal stability
: With the UVRAS principle low ranges of NO, NO2, SO2 ( ppm) can be accurately and individually measured.
: Using the NDIR principle to measure CO in low ppm ranges (20 ppm) can be achieved. New Mounting of the NDIR bench on rubber supports reduces vibration sensitivity.
: Using the paramagnetic measuring principle to analyze O2
: Latest cold dry CEMS analyzer technology UNOR & DEFOR with an excellent value for CCPP
: SICK MAIHAK GmbH Power_CEMS forCCPP_en_2012_09 11

28. Emission monitoring Application-specific fully configurable system
Central control unit
Dust, volume flow (in situ)
Connecting additional networks using standard interfaces
High-grade analyser modules and components
All required gas components (extractive) (SO2, NO, NO2, NH3, HF, CO, CO2, CH4, HCl,N2O, H2O...) 28

29. Thank you for your attention.