Continuous Emission Monitors (CEMS) Advancements From Measuring HCl and Ammonia (NH3) to using Sensitive Moisture Measurements for Identifying Boiler Tube

Leaks

Ronald L. BakerRobert Peters

Edul Chikhliwala

EcoChem Analytics

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

Hot-Wet Sampling System

Gas Filter Correlation

Reference (I0)

The radiation intensity is measured with the Gas-filled cell in the optical path

Measure (I)

The radiation intensity is measured with the free aperture in the optical path

Gas Filter Correlation

Single Beam Dual Wavelength

Reference (I0)

The radiation intensity is measured with the Reference filter in the optical path

Measure (I)

The radiation intensity is measured with the Measure filter in the optical path

Single Beam Dual Wavelength

MC3 Analyzer Optical Path

System Components

MC3 Measurement Capability

* All components at 185C 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

Gas Range Interval**

CO 0-5 PPM to 0-10,000 PPM

SO2 0-10 PPM to 0-1,000 PPM

NO 0-5 PPM to 0-500 PPM

NO2 0-5 PPM to 0-500 PPM

CO2 0-1,000PPM to 0-40%

NH3 0-5 PPM to 0-500 PPM

HCl 0-10 PPM to 0-100 PPM

H2O 0-2% to 0-50%

O2 0-25%

Single MC3 analyzer can measure 8 gases plus Oxygen

Dual ranges can be selected for same gas

N2O 0-10 PPM to 0-1,500 PPM

CH4 0-10 PPM to 0-1,000 PPM

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

EcoChem MC3 Systems – Waste Coal

HCl, Ammonia and Water Calibration

“Wet” Calibrations with the Hovacal unit

Evaporator

MassFlow

Controller

Temperature ControlPump

Solution (pure water, NH3 or HCl)

Carrier Gas

Hot-WetVapor Mixture

Balance

Liquid

MassFlowMeter

(Optional)

Supply Unit

MC3 Installations - HCl

• Wasatch Integrated Waste Mgmt– 2 waste to energy units

• Wheelabrator Falls – PA– 2 waste to energy units

• Chemical & Waste Treatment Industry worldwide- 15+ analyzers including Eli Lily & Company

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

HCl Dedicated CEMS

• Major Utility in Texas• Installation near Dallas

Question and Answers

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