Simultaneous process and emission monitoring through two automatically

Transcription

1 Simultaneous process and emission monitoring through two automatically Simultaneous process and emission monitoring through two automatically Speaker: Luigi Fiorani Authors: Luigi Fiorani Davide Tittarelli Stefano Collura CEM th International Conference and exhibition on Emissions monitoring 16th May 2014

2 Presentation Outline Company Overview Loccioni Group Results and Benefits Normal working condition operations Automatic Switching Operations Manual Switching Operations Additional results Introduction Conclusion Materials and Methods Description of the plant Description of the CEM system Description of the switching system Configuration of the swtiching system Developments

3 Loccioni core compentences Measure & testing Design and manufacturing of testing systems for the quality control of products and processes Industrial Automation Integrated solutions for production optimization and quality monitoring Energy Efficiency Integrated solutions for energy saving, production, storage and monitoring

4 What we do We research, design and produce innovative solutions to improve the quality, the efficiency and the sustainability of products, processes and buildings. Assembly, testing and quality control systems for industry appliances Automating and quality control solutions for health care Integrated solutions for energy independence Integrated solutions for environmental and process monitoring Assembly, testing and quality control systems for automotive components

5 Overview Context Materials and Methods Description of the CEM system Description of the switching system Configuration of the swtiching system Results and Benefits Normal working condition operations Automatic Switching Operations Manual Switching Operations Additional results Conclusion Developments

6 Context In addition to the continuous emission monitoring, some kind of productive plants are usual to adopt an additional system for the control of gaseous stream along the process. The production of nitric acid (HNO 3 ) represents a typical example where a double control is used. The main issues of such a plant are: Environmental impact of the process: emission from 100 to 3500 ppm of NOx (NO + NO 2 ), responsibleof acid rains and ground-level ozone production An abatement of NOx is required: usually it is conducted through the Selective Catalytic Reduction (SCR) process with injection of ammonia (NH 3 ) Process control of ammonia injection: problems of corrosion effect, ammonia salt formation and waste of reagent. Starting from that, an innovative solution for the emission control and process monitoring has been developed and engineered by Loccioni for a production plant in Italy

7 Description of the CEM system The system is based on 2 LOCCIONI GIGAS 10M FT- IR Spectrometers (TUV certified) Each analyzer is placed within a cabinet: the complete CEM system is represented by Loccioni GCS (GIGAS FT-IR CEM SYSTEM) Both cabinets are put inside a shelter containing the equipment for the conditioning and the treatment of sampled gas, before entering into the analyzers. Components measured by GIGAS FT-IR analyzers: Measuring Range Type of Gas Emission Process NO ppm ppm NO ppm ppm NH ppm ppm ppm ppm N 2 O ( ppm) ( ppm) GCS: GIGAS FT-IR 10 M CEM System

8 Description of the CEM system : GCS (Gigas FT-IR CEM System) GIGAS FT-IR is the multi-component analyser designed from the research@environment developed to guarantee high quality, accuracy, reliability and strength. GIGAS FT-IR analysers work with Fourier-Transform InfraRed spectroscopy measurement principle. Thanks to the spectroscopic analysis of infrared spectrum, GIGAS FT-IR analyser is able to reveal the type and the concentration of the molecules inside the gas to be analysed. Features Dynamic real-time alignment of the interferometer optics to be robust against vibrations, spectral shift and thermal or mechanical shocks Modular layout: various accessories can be coupled with the same interferometer bench module to satisfy all requests Large spectral library to identify and quantify over 300 chemical compounds Heated cell (180 C) to prevent moisture condensation High quality materials and coatings to prevent corrosion by acid components Adjustable optical pathlength Scan velocity, spectral resolution, signal processing and other interferometer settings can be easily modified via software CERTIFIED BY TÜV RHEINLAND ACCORDING EN15267 STANDARD

9 Description of the switching system The two measuring systems allow to simultaneously and independently analyze samples extracted at two different points of the same nitric acid stream: The nitrogen oxides control is performed before and after the NO x abatement: the downstream measurements are allowed by the CEM system

10 Configuration of the swtiching system In case of breakdown of CEMS, the sampling system automatically switch in order to deliver the emission stream to the other analyzer. The switching system works through a system of electro valves managed directly by PLC that manages the alarms of both the analysis systems. Switching Normalof functioning the analyzers

11 Results and Benefits Normal working condition Operations The system allows contemporarily the emission monitoring and the process control by comparing the measurements before (upstream) and after (CEMS) the DeNOx abetment system The system allows the possibility of changing the full scales of the measuring gas by simply varying the software (a changing of N 2 O measuring range has been done) Automatic Switching Operations Automatic Switching activates every time a sudden failure of the CEMS occurs This operation allows for the avoidance of any interruption of the transmission of emissive data to the authorities The activation of automatic switching has occurred two times since the installation (2008), avoiding: interruption in data transmission to environmental authorities; the stop of the Nitric Acid production due to a CEMS maintenance the intervention of equip for manual sampling and analysis of gas. After the switching, the measuring range of each analyzer is set automatically depending on the kind of flue gas to be measured (process or emission)

12 Results and Benefits Manual Switching Operations During the maintenance, the system used for process monitoring upstream the DeNOx reactor has been used as backup CEMS: this allows not to stop the production process. Possibility to cross-check the reliability of the measurements by simply changing temporarily the gaseous flow from one analyzer to the other one, in order to compare their values and verify eventual damage of the analyzer. Additional Benefits The customer has found a main benefit in switching the two systems once every week manually: this procedure has allowed to obtain a controlled wear of the two systems, while reducing ordinary maintenance time and costs and the occurrence of extraordinary failures. Eventually, it is also possible to add new compounds to measure: even in this case no hardware modification of the analyzers is required. In case of alarms of the sampling lines, the system is able to autonomously put into safety mode: the software operates through solenoid valves to allow the flux of inert gas replacing the measuring gas (preserving the moisture-sensitive components of GIGAS 10M FT-IR analyzer)

13 Conclusions The system combines the advantage of the emission monitoring and the process control with the cost effectiveness due to the fact that each analyzer can be used also as the backup of the other. Several benefits have been found for the customer: For two times, the automatical switching of the analyzers allowed the backup of the CEM system During the normal functioning, the process monitoring allows the precise control of ammonia injection for the NOx abatement system No interruptions of acquired data during the maintenance occurred The measuring range of the analyzers are automatically set depending on the kind of measure to perform (process or emission) Even in the worst case (failure of the sampling line) the system is able to autonomously put into safety mode. The system allows to change the measuring ranges or add new components by simply varying the software The possibility of switching gaseous flow from one analyzer to the other helps to keep the highest reliability from both emission and process monitoring systems

14 Developments Starting from this first case history, several solutions involving more GIGAS 10 M FT-IR analyzers linked to each other through a switching system have been developed. An example is the represented by the solution engineered for a coal-fired power in Italy. Main features of the solution The system is used as for the continuous gas composition analysis on two stacks The analysis is simultaneously and independently carried out by two Loccioni GIGAS FT-IR Analyzers An additional analyzer is used, if needed, as backup system for both the stacks In case of breakdown of one of the two analysers, an automatism permits to commute the relative extractive point on the third analyser. Through this mechanism the system, working through electrovalves managed directly by the PLC, allows the backup on the CEMS, assuring the continuous flux of data without interruptions for both the stacks

15 Thank You for Your attention Luigi Fiorani R&D Environment environment.loccioni.com