steam equipments- cems for sox/nox emission & …soxnox2019.missionenergy.org/presentations/steam...
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STEAM EQUIPMENTS-
CEMS FOR SOX/NOX
EMISSION & PROCESS
CONTROL MONITORING
SOLUTION
� INSITU CEMS
� EXTRACTIVE CEMS
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STEAM EQUIPMENTS PVT LTDSTEAM EQUIPMENTS PVT LTDAn ISO 9001:2015 certified Company
SEPL was established in 2004 with an idea and concept to reach the OEMs & End users
to design and supply high quality CEMS & Process control Equipments to meet wide
ranges of application including Hazardous area.
Vision :
� To be a globally renowned CEMS & Process & Safety control Monitors
� To support OEMs ,End Users ,Consultant ,EPC contractor by offering total solution
� To have systems designed & certified to Global standards.
� We Promise to reduce at least one hour of Maintenance Engineer per day
� To improve profitability of customer through Higher Reliability & better process efficiency
Quality Policy : ISO-9001:2015 certified, CE
Safety : Safety off all our stake holders is driving factor of SEPL
Manpower :
Present manpower of 150+ Employees & established Sales and Service network.
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Manufacturing Locations and Group Companies
INDIA Middle East (MEA) USAPlant : I (12,000 Sq. Ft) Steam Equipments Pvt Ltd Steam Equipments IncSteam Equipments Pvt Ltd C/o Omega Engineering 1018, West Grove, OrangePlot No.44, 49, 50 Tiny Industrial Estate, P6 084, SAIF Zone, CA – 92865-4129Kondhwa Budurk, Pune , India Sharjah, UAE United States of America
Plant : II (40,000 Sq. Ft) South Africa Spain
Steamlok Engineering Pvt Ltd Steam Equipments Africa Pty. Ltd. Steam Equipments Pvt. Ltd.
Plot No-200/201, Mahalunge E8 Pinelands Office Park, C/o Esindus S.A
Chakan Industrial Estate, Modderfontein Avda. Manoteras, 42- 28050
Pune 410501, India Gauteng Province, South Africa Madrid , Spain
Plant : III (60,000 Sq. Ft) Singapore (SEA) Madrid , Italy
Steam Equipments Pvt Ltd (SEZ) Steam Equipments Pte Ltd Steam Equipments SRL
Plot No – 9, MIDC, Kesurdi, Satara Dist. NO 73 UBI ROAD 1, # 09-55 Registration is under process
Maharashtra, India OXLEY BIZHUB
SINGAPORE 408733 Saudi Arabia
Steam Equipments Pvt. Ltd.
Registration is under process
17-09-19 3
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Markets Served
Chemical & Power & Steam Oil & GasPulp & Paper
Petrochemical upstream
Water & Waste
Water
Food & Beverage Oil & Gas
downstream
Metals, Mining
Minerals
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CEMS TECHNOLOGY COMPARISON:IN-SITU Ana.
Sr. No.TECHNOLOGY COMPARISON
Item In-situ UV-DOAS Hot-Wet Method In-situ NDIR & IR GFC
1 Measuring rangeSuitable for low and high
concentrations.Suitable for high level of concentration.
2 Sampling System No sampling requirement Proper purging system is mandatory.
Requires less calibration because of 3 Calibration check
Requires less calibration because of
low drift.usually requires more calibration checks.
4 MaintenanceLow maintenance as there is no
moving part.
high maintenance due to sampling system
component. stack gas may corrode the probe
and optics,
5 Process conditionsWorks well in harsh conditions like
High moisture.
widely used technique in harsh process
applications
6 Measurement of NOX Measures NO & NO2 both separatelyMeasures NO and not NO2. NO2-NO converter
required
7 Effect of dust LOWHigher effect but can be controlled with
inbuilt mechanism
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CEMS TECHNOLOGY COMPARISON: :IN-SITU Ana
Sr. No. TECHNOLOGY COMPARISON Item In-situ UV-DOAS Hot-Wet Method In-situ NDIR & IR GFC
8 Calibration & Check frequency
1. Diagnostic check in every cycle 1. Daily ZERO Check
2. Six monthly ZERO and SPAN Calibration2. Fortnightly ZERO and SPAN
Calibration
3. Yearly Linearity Check 3. Six Monthly Linearity Check
4. After Major maintenance multipoint
Zero and SPAN Calibration
4. After Major maintenance
multipoint Zero and SPAN Calibration
9 Replacement of analyser spare Easy Difficult 9 Replacement of analyser spare Easy Difficult
10 Source Life around 10 years UV lamp life 3-4 years IR source life
11 Effect of moistureIf moisture over 40%, instrument gets
effected
Very much affected, need to measure
H2O online
Cannot work below dew point (below
95 degC)
12 Anti-Interference
The combination of complete &
continuous absorption spectra, high
wavelength resolution, DAOS algorithm
erases interference from dust, moisture
and background gases
Vulnerable to moisture interference
13 Gas Cell Connected by optical fiber, easy to replace
and low maintenance cost Complex to replace and maintenance
14 Reliability No moving parts in analyzerMoving parts in analyzer like chopper
motor
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CEMS TECHNOLOGY COMPARISON: Extractive Ana.
Sr. No.TECHNOLOGY
COMPARISON Item Extractive UV-DOAS Hot-Wet Method Extractive NDIR/ IR GFC/ IR CFM and NDUV
1 Measuring range Suitable for low and high concentrations. Suitable for high level of concentration.
2 Sampling System No sampling requirement
sampling system required like sample gas
cooler, moisture filter, electrical pump,
moisture detector,NO-NO2 converter
High due to the Sampling system component 3 Power Consumption Low due to No Sampling system requirement
High due to the Sampling system component
like pump ,Sample cooler , Moisture controller
4 Calibration check Requires less calibration because of low drift. usually requires more calibration checks.
5 Maintenance Low maintenance as there is no moving part.
high maintenance due to sampling system
component like sample gas cooler, moisture
filter, electrical pump, moisture detector,NO-
NO2 converter
6 Process conditions Works well in harsh conditions like High moisture.widely used technique in harsh process
applications
7 Measurement of NOX Measures NO & NO2 both separatelyMeasures NO and not NO2. NO2-NO converter
required
8 Effect of dust LOWHigher effect but can be controlled at sampling
point
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CEMS TECHNOLOGY COMPARISON: Extractive Ana.
Sr. No. TECHNOLOGY COMPARISON Item UV-DOAS Hot-Wet Method Extractive NDIR/ IR GFC/ IR CFM
and NDUV
9 Calibration & Check frequency
1. Diagnostic check in every cycle 1. Daily ZERO Check
2. Six monthly ZERO and SPAN Calibration2. Fortnightly ZERO and SPAN
Calibration
3. Yearly Linearity Check 3. Six Monthly Linearity Check
4. After Major maintenance multipoint Zero
and SPAN Calibration
4. After Major maintenance
multipoint Zero and SPAN
Calibration
10 Replacement of analyser spare Easy Difficult
11 Source Life around 10 years UV lamp life 3-4 years IR source life
12Effect of moisture
If moisture over 40%, instrument gets
effectedlow as removed or Hot Wet
13 Anti-Interference
The combination of complete & continuous
absorption spectra, high wavelength
resolution, DAOS algorithm erases
interference from dust, moisture and
background gases
Vulnerable to moisture
interference
14 Gas Cell Connected by optical fiber, easy to replace
and low maintenance cost
Complex to replace and
maintenance
15 Reliability No moving parts in analyzerMoving parts in analyzer like
chopper motor
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Comparison between other make Analyzer
CEMS & SEPL make CEMS P&ID diagram
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CEMS POWER LOAD CALCULATION COMPARISON
SR No INSTRUMENTOther make CEMS
Total WATT /UNIT
SEPL make CEMS Total WATT
/UNIT
1] UPS LOAD
1 CEMS ANALYSER 150 120
2 NO-NO2 CONVERTOR 85 N/A
3 SINGAL STAGE SAMPLE GAS COOLER 300 N/A
4 ELECTRICAL SAMPLE PUMP 750 N/A
5 PERISTATIC PUMP 100 N/A
6 MOSITURE CONTROLLER &DETECTOR 50 N/A
7 HEATED SAMPLE PROBE 500 500
TOTAL Power
requirement Per
CEMS (WATT)
8136 4368
Difference between
both CEMS(WATT)3768
7 HEATED SAMPLE PROBE 500 500
8 PLC SYSTEM & TIMER 80 80
9 COMMUNICATING HARDWARE 50 50
10 UTILITY SOCKET 200 200
11 SOV (230VAC) 72 72
12 SPM ANALYZER 50 50
13 24VDC POWER SUPPLY 400 200
TOTAL POWER IN WATT (UPS) 2787 1272
UPS TOTAL ( 25% EXTRA) WATT 3483 1590
2) NON UPS LOAD,
1 HEAT TRACER LINE 2200 2200
2 TUBE LIGHTS ( 230VAC ) 22 22
3 PANEL AIR CONDITIONER (230VAC) 1500Only required when ATM temp. is
more than 50 Deg. C
TOTAL POWER IN WATT (NON-UPS) 3722 2222
NON-UPS TOTAL ( 25% EXTRA) WATT 4653 2778
both CEMS(WATT)
Calculate on 70%
Load factor
3.768(KWH)
*24*365*0.7
23105 KWH * 7 INR
TOTAL POWER
SAVING PER YEAR161735.00 INR
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Maintenance benefits of SEPL make Ana.
� No moving parts as against chopper motor ,sample pump ,Peristatic pump etc. in
other models
� No spare parts required e.g. in other designs ,moisture traps, moisture sensor,
filters, Pump rebuilt kits are required to be kept as spares.
� Calibration frequency is lower & hence less calibration standard required.
� Source life guaranteed is 10 years as against lower NDIR source.
Service Support� All India 25 service Engineer support for CEMS analyzer erection, commissioning
and immediately troubleshooting.
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INSITU CEMS Installation :-
1. PARAG MILK FOODS LTD.-MAHARASTRA 2. TRELLEBORG LANKA (PVT) LTD. (Sri Lanka)
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INSITU CEMS Installation :-
3. GREENLAM INDUSTRIES LTD. Rajasthan INSITU remote calibration & Auto Purging JB
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Extractive CEMS Installation :-
1. MARINO LAMINATES, Haryana
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Extractive CEMS Installation :-
2. BALRAMPUR CHINNI MILLS ,BALRAMPUR
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SEPL make CEMS supply Success Stories
Sr.No. Project and package Customer name supplied itemPO/REF NO/ Date
Supplied
Qty Date of supply1 Parag Milk Foods ltd Parag Milk Foods ltd CEMS 4400000786 1 Nos. 05-07-2019
2 BALRAMPUR Group BALRAMPUR CHINI MILLS LTD. CEMS BCM/CEMS/2018-19/431 3 Nos. 13-07-2019
3 Thermax Ltd Marino Panel CEMS 3171787 1 Nos. 04-02-2019
4M/S Isgec Heavy
Engineering LtdGallant ishpat ltd CEMS P10129298/JB1083 1 Nos. 01-06-2019
5THYSSENKRUPP INDUSTRIES
INDIA PVT.LTDShukhbir project-Faridkot CEMS 2500013863 1 Nos. 10-06-2019
6THYSSENKRUPP INDUSTRIES
INDIA PVT.LTDShukhbir project-Ferozepur CEMS 2500013864 1 Nos. 10-06-2019
7M/S Isgec Heavy
Engineering LtdUP state Sugar, Gorkhpur CEMS P10131989/JB1091 2 Nos. 21-06-2019
8 Thermax Ltd CEAT Nagpur & CEAT Halol CEMS 40049789 2 Nos 30-06-2019
9 Thermax Ltd CEAT Chennai CEMS 40050234 1 Nos. 30-06-2019
16
9 Thermax Ltd CEAT Chennai CEMS 40050234 1 Nos. 30 06 2019
10GREENLAM INDUSTRIES
LIMITED
GREENLAM INDUSTRIES
LIMITEDCEMS 1440000522 1 Nos. 01-07-2019
11ISGEC Heavy Engineering
limitedShun Shing CEMS P10135166/JB1026 1 Nos. Under Execution
12ISGEC Heavy Engineering
limitedDwarikesh Sugar CEMS P10134905/JB1128 1 No Under Execution
13 Atul Ltd Atul Ltd CEMS IN/ENL/919000182 1 No Under Execution
14 Uttam Energy System Ltd CEMS PDD001018 1 No Under Execution
15ISGEC Heavy Engineering
limitedTwenty One sugar CEMS P10137757/JB1093 1 No Under Execution
16 Thermax Ltd Trelleborg-Srilanka CEMS 40047567 1 Nos 20-03-2019
17Greenlam Industries
LimitedGreenlam Industries Limited
CEMS
4200003016
1 No Under Execution
18Greenlam Industries
LimitedGreenlam Industries Limited CEMS 4200003018 1 No Under Execution
19 Thermax Ltd Birla Century CEMS 1 No Under Execution
20INDPRO ELECTRONIC
SYSTEMS (INDIA) PVT. LTD. M/s Parle Biscuits Pvt Ltd CEMS 97082/IS 1501/2019-20 1 No Under Execution
21 Volant Analytics CEMS 1880719 1 No 15-08-2019
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Why we need DeNOx Online Monitoring ?
� SCR DeNox Process
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Why we need DeNOx Online Monitoring ?
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Pulverized Coal Fired Plant Layout &
Measuring points and solutions
Sr. No.Measurement
PointTemp. Pressure
Measurement
Components
Detections
Purpose
Recommend
products
1The main emission
stackNormal
Slight
positive
pressure
CEMS
(SO2,NOX,CO,O
2,H2O,Temp.,
Pressure &
Online monitior
concentration of
emission
components
Insitu UT-IN-S-N-O
or Extractive UT-
EX-S-N-C-O and IM-
TPF 100pressure
Flow)components TPF-100
2 SCR downstream Normal
Slight
positive
pressure
NH3:0-10 ppm
Monitor fuel
combustion
condition adjust
production device
,realize
denitration
optimization
Cross duct UT-IN-
NH3 & EXINSITU UT-
EX-NH3
3 SCR downstream Normal
Slight
positive
pressure
NOX:0-2000
mg/m3 ,
O2:0-25%
Online monitior
SCR efficiency
Extractive UT-EX-N-
O
4 SCR upstream Normal
Slight
negative
pressure
NOX:0-2000
mg/m3 ,
O2:0-25%
Online monitor
SCR efficiency
Extractive UT-EX-N-
O
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FGD ApplicationThe requirement for Flue Gas Desulphurisation (FGD):-
� In the combustion of coal, oil, waste and in the production of metals from ores, large amounts of SO2 are produced. SO2 can have a harmful effect on human health and damage to the natural environment. Lead to development of Flue Gas Desulphurisation technics, that removes SO2 from the flue gas prior to release to the atmosphere.
� In order to reduce SO2 emission, coal fired power stations across the world have been fitted, or are in the process of retrofitting SO2 scrubbers.
� Nearly all SO2 control methods works on the principle that alkali sorbent sprayed in the flue gas reacts with acidic in nature SO2, also with HCl and HF. Reaction products are captured in dust filters (Dr y FGD), precipitates from gypsum slurry in the sump (Wet FGD), or it is disposed after treatment to the sea (Sea Water FGD).
� The most commonly used sorbent in the desulphurisation process are: limestone, lime, hydrated lime.
What we do
In order to control FDG systems, these processes require monitoring throughout. SEPL offer a range of products that can monitor both input and output gases, flow & dust emissions reliably and accurately using the very latest technology.
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FGD TechnologiesComplete dry systems (injecting dry sorbent, lime or bicarbonate)
� In a dry sorbent injection (DSI) process dry sorbent is injected to the flue gas stream. This reacts with SO2 and other acid gases which are captured downstream in dust filter.
� Due to low efficiency in capturing SO2 ranging from 50 to 70%, nowadays this process has a small share in FGD plants.
Semi-Dry :- Type 1-Spray Dryer Absorber (SDA with hydrated lime)
Type 2-Circulating Dry Scrubber (CDS/NID with hydrated lime)
� Semi-dry FGD are typically installed on smaller facilities, often being a good alternative to � Semi-dry FGD are typically installed on smaller facilities, often being a good alternative to Wet FGD on sites that are retrofitting FGD plants.
� In Semi-dry process, although water is added, gas is maintained above the saturation point (dew point). Typical DFGD operation temperatures are 15-20°C above dew point (70 to 75°C).
� Semi-dry FGDs are typically integrated with downstream fabric filter that collects reaction products in a dry form.
Wet Scrubbers :- Type 1-Lime or limestone slurry
Type 2-Sea water washing SWFGD
� Wet Lime Scrubbers are a predominant FGD process, typically installed on the large facilities where low quality high sulphur coal is used.
� In the wet absorbers, flue gas is sprayed with lime slurry. In the process gas is cooled below saturation temperature, resulting in high efficiency in capturing acid gases.
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Pulverized Coal injection Plant Layout
& Measuring points and solutions
Sr. No.Measurement
PointTemp. Pressure
Measurement
Components
Detections
Purpose
Recommend
products
1
Coal pulverizer
entrance or hot
blast stove 100 350°C
Slight
positive O2:0-21% ,
Security
monitoring, Cross duct UT-IN-C-
22
1 blast stove
emission gas down
stream
100-350°C positive
pressure
21% ,
CO:0-3000ppm
monitoring,
prevent
explosion
O
2Coal pulverizer
down stream100-350°C /
O2:0-21% ,
CO:0-3000ppm
Security
monitoring,
prevent
explosion
Extractive UT-EX-C-
O
3Pulverized coal
bunkerNormal
Slight
positive
pressure
O2:0-21% ,
CO:0-3000ppm
Security
monitoring,
prevent
explosion
Extractive UT-EX-C-
O
4Bag-type dust
collector200°C /
O2:0-21% ,
CO:0-3000ppm
Security
monitoring,
prevent
explosion
Cross duct UT-IN-C-
O
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In Situ System
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SEPL INSITU CEMS with Dust and flue gas
data
� Continuous Emission Monitoring system(CEMS) consists of particulate matter monitoring subsystem, Gaseous pollutants monitoring subsystem, Flue gas parameters monitoring subsystem, System control and Data acquisition and processing subsystem.
� It can monitor gases such as SO2,NOx,CO,CO2/O2,Dust,temperature,pressure,flow rate, humidity etc. rate, humidity etc.
� it can also be extended for a specific occasion to monitor HCL,HF,CO,CO2,NH3,H2S,CL2,VOC and other parameters.
� The measured gas passes through sampling probe for deducting ,heating tube for sampling ,then goes into the gas analysis module(Ultra violet differential optical absorption-spectroscopy(DOAS) for analysis .
� It effectively eliminates problems of dust and moisture interference on analysis
� Particularly in the case of low concentration measurements is an unparalleled advantage
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� principle of in-situ: UV DOAS & TDLAS
� No need sampling /direct monitoring
� quick response time
� low maintenance costs
SEPL -CEMS In Situ System
� no interface of dust and humidity
� SO2,NOx,CO,CO2 ,NH3 Multi gas measuring
� Suitable for stack of Sugar Boilers , CPP, Power, Steel, Cement, Textile, furnaces
� CPCB Connectivity with Remote calibration
� Very low maintenance costs
� Calibration frequency: once in 1 months
� UV / TDLAS BASED: HIGH ACCURACY
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INSITU Ana. for Hazardous area application
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SEPL CEMS In Situ systems
Features Specification
principle UV DOAS & TDLAS
Accuracy ≤± 2%F.S
Communication RS232/RS485
Repeatability ≤± 0.5 %F.S. UV DOAS based SO2 & NOX and ≤ 1% TDLAS based
CO
Zero & Span Drift ≤± 1 % F.S./30 day (UV DOAS based SO2 & NOX) and ≤± 1 % Zero & Span Drift ≤± 1 % F.S./30 day (UV DOAS based SO2 & NOX) and ≤± 1 %
F.S./6-month TDLAS based CO & CO2
Response Time
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SEPL CEMS Flue Gas Data Methodologies
measurement
index
parameter Range(min-max) Measuring principle
SO2 (0-500 ppm)(0-5000
ppm)
UV DOAS Technology
NOX (0-500 ppm)(0-5000
ppm)
UV DOAS Technology
ppm)
CO (0-500 PPM)(0-5000
ppm)
TDLAS Technology
TDLAS Technology
Electrochemical or zirconia
(0-5%) (0-20%)
0-25%CO2
O2
Dust (0-20 mg/m3) (0-
10g/m3)
Innovative Dynamic Detection (DDP) or
laser forward or backward scattering
Temp 0-3000c(customizable) Thermal resistance and thermocouple
Press -10kpa
+10kpa(customizable)
pressure sensor
Vel. 0-40m/s(customizable) pilot tube
humidity 0-40% humidity capacitance or dry wet oxygen
method
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Extractive System
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SEPL CEMS Extractive system
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SEPL CEMS Extractive system
� By the working of high temperature sampling pump, flue gas passes sampling
probe (filter cartridge included), heat tracing pipe, ball valve, secondary
filter, then enters analysis mode and is discharged at last,
� The whole process is with above1200c heat tracing in case of any corrosion
and blocking caused. and blocking caused.
� To avoid filter cartridge being blocked by dust, system should periodically
close ball and control purge valve to provide pulse purging for probe.
� This analyzer supports automatic (zeroing and span calibration).Measurement
flow path closes when calibration is carrying out. Secondary filtration has
protection function to protect analysis module when probe is leaking and
temperature controller fails.
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SEPL CEMS Extractive type systems
Features specification
principle UV DOAS & TDLAS
Accuracy ≤± 2%F.S
Communication RS232/RS485
Repeatability ≤± 0.5 %F.S. UV DOAS based SO2 & NOX and ≤ 1% TDLAS
based CO based CO
Zero & Span Drift ≤± 1 % F.S./30 day (UV DOAS based SO2 & NOX) and ≤± 1 %
F.S./6 month TDLAS based CO & CO2
Response Time
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SEPL UV DOAS CEMS Principle
The analyzer adopts UV differential optical absorption spectroscopy (DOAS) which can precisely measure
concentrations of trace gases using absorption spectrum of gas component. The basic principle is to identify
gas molecule with the narrow-band of detected molecule.
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EMERGING TRENDS & CHALLENGE FOR
FUTURE TO SOX/NOX MONITORING
� Norms in developing countries like India will next few
years adopt European/USEPA standards requiring very low
ranges of measurement thus posing challenges to NDIR &
equivalent technologies.equivalent technologies.
� Modern FGDS may call for accurate measurement of HCL
in very low ranges in addition to SOX giving rise to use of
LASER technologies like TDLAS, QCL ,Intraband Laser etc.
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For more details contact :
Analysis-Monitoring- Performance
For more details contact :
Cell: 91 -7888053998 & 91-9725728049
For enquiries: [email protected]