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• Welcome to the ABB eLearning program for Continuous Gas Analyzers Basics.

This course module will familiarize you with the applications and application areas

of gas analysis. If you need assistance navigating through this module, click the

help button at any time. To view the speaker notes, select the speaker notes

button in the lower right. Also, if you like, you can download a printable version of

the presentation by clicking the “Attachments” button. And now: Enjoy the course!

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• After completing this module, you will be able to…

• name the main industrial sectors, where ABB sells CGA analyzers

• identify the measuring points in the major applications

• select the right analyzer modules for major applications

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• Let‟s get started with combustion processes: The most important area of

applications for continuous gas analysis. Combustion processes can be found in

many different industrial areas, like

• the generation of heat

• and electricity,

• Process steam production,

• Municipal and hazardous waste incineration,

• Surface treatment for example in annealing processes,

• Melting processes as used in metal or glass production,

• Roasting process for example iron ore roasting, sintering,

• Steel production and

• Cement production, … to name only the most important.

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• Combustion processes are the major sources of air pollution.

• Fossil fuels like natural gas, coal or oil, but also waste (for instance vehicle‟s tiers)

and biomass represent the major basis of energy sources.

• Combustion of these components leads to gaseous pollutants.

• The outlet of pollutants containing exhaust gas into the atmosphere is called

emission.

• The measurement of pollutants is called emission monitoring. Due to the harmful

effect on the environment and the global warming potential of these components,

tremendous effort is made to reduce the pollutants in exhaust gases, by

• … combustion optimization, and … exhaust gas treatment. What are the major

components in exhaust gas we want to measure?

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• Carbon-dioxide, water and nitrogen

• In reality combustion is incomplete. This leads also to carbon-monoxide,

hydrocarbons and excess oxygen.

• Sulphur, which is present in many fuels, plus nitrogen from air will form sulphur

dioxide and nitrogen oxides

• Especially in waste incineration hydrogen chloride and hydrogen fluoride are

found.

• Mercury and particulates are also emitted. Next we will see the typical measuring

points, which are also called sampling points, where measurement takes place.

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• A coal fired power plant can be used as a representative example of all kind of

combustion processes. This is independent of the purpose of energy production or

fuels used.

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• Combustion efficiency

• Ideal combustion needs the right amount of oxygen.

• The oxygen value can be measured with a paramagnetic

• oxygen analyzer like Magnos206

• Efficiency of DeNOx process. Nitrogen oxide and nitrogen dioxide are a major

cause for environmental damage.

• These components are removed by injection of ammonia.

• The injection of ammonia is regulated via the NO/NO2 concentration in the

exhaust gas. The efficiency of this process is controlled by monitoring the outlet

for excess ammonia. Analyzers used are infrared photometer

• Uras26 for NO

• or alternatively ultra-violet photometer Limas11UV for NO and NO2, and laser

analyzer LS25 for NH3 measurement.

• Electrostatic precipitator. The typical measuring component in this part of the

process is carbon monoxide. Since CO is a flammable gas this measurement

represents

• a safety measurement to avoid explosions.

• The suitable analyzer is the Uras26 photometer.

• Efficiency of the DeSOx process (desulfurization). The efficiency of the flue

gas desulfurization is monitored

• by measurement of SO2 with Uras26.

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• Analyzers that are used in emission monitoring have to accomplish legal

requirements depending on local legislation.

• This requires approvals or certificates issued by testing institutes like the German

TUV or other certification bodies worldwide.

• Both analyzer series, Advance Optima as well as EasyLine are certified according

to international standards, as required by the European Union and US EPA. These

analyzers can be applied in emission monitoring worldwide.

• Typical measuring components for emissions are: CO, NO, SO2 and O2.

• The analyzers used are Uras26 and Magnos206.

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• Another application that is not linked to emission monitoring or process control can

be found in power production:

• the leakage monitoring of hydrogen in a cooling system of turbo generators.

• In order to increase efficiency of turbo generators, it is necessary to cool them.

Hydrogen is used due to its higher thermal conductivity, compared to air, to make it

more effective.

• However, hydrogen is potentially explosive in mixtures with air.

• Caldos27 is used to monitor the cooling gas continuously. This is called a safety

measurement

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• We have already talked about the measuring points in process control and

emission monitoring in a power plant. These measuring points can also be found

in waste incineration plants.

• Combustion control. CO measurement with Uras26 and oxygen with Magnos206

and protection of electrostatic precipitator.

• Process control of scrubber 1. HCl removal and SO2 removalwith Uras26

• Monitoring the ammonia dosing to the DeNOx process with Uras26 or LS25.

• Activated charcoal filter to remove dioxins and hydrocarbons. Safety

measurement to monitor random occurrence of partial self-ignition of the activated

charcoal.

• Emissions Monitoring. According to local legislation with ACF-NT (for all

components CO, CO2, NOx, SO2, HCl, and HF) plus Multi-FID14 for total hydro

carbon measurement.

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• Cement is the basic ingredient in concrete which is the key building block for

construction industry. Cement is typically made from limestone and clay. These

raw materials are extracted from a quarry and crushed to a very fine powder. This

raw material is called the 'kiln feed' and is heated

• in a rotary kiln to temperatures of about 1400 °C to 1500 °C.

• The material formed in the kiln is described as clinker.

• Cement production is one of the world‟s most energy intensive industries. Let‟s

have a look at the important sampling points in a cement plant.

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• Measuring point 1: Coal silo. A major threat in coal silos is the random occurrence

of smoldering.

• This leads to elevated CO concentration with the danger of explosion and toxic

impact. The CO measurement is done with an Uras26.

• Measuring point 2: Calciner. CO and O2 values are measured for optimizing and

controlling the combustion for lower fuel consumption. CO is measured with

Uras26 and O2 with Magnos27.

• Measuring point 3: Electrostatic filter. To protect the electrostatic filter from

explosions CO is measured as well as oxygen.

• Measuring point 4: Stack - Continuous emissions monitoring. Depending on

international requirements for emissions monitoring a number of gas components

have to be measured continuously: The components are: CO, NOx, SO2 and

depending on the fuel used

• additionally HCl, HF and Total Organic Carbon. Analyzers used: Uras26,

Magnos206, MultiFID14 or alternatively the ACF-NT multi-component system

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• Measurement at the kiln gas inlet is one of the most crucial measuring tasks. As

you can imagine the

• high dust load and the

• high temperatures are very challenging requirements for the gas sample handling

system.

• ABB Analytical can offer a complete solution for both, continuous gas analysis and

sample handling.

• The analyzers, the gas cooler and the sample gas feed unit are integrated in a

standard system that is called ACX. The gas sampling probe and the retractor

system – that moves the probe in and out the rotary kiln – are called the SCK. This

system assures:

• Validation of clinker quality,

• minimization of fuel costs and

• optimization of combustion control

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• Beyond emissions monitoring many other applications can be found in chemistry

and petro-chemistry.

• One of the most important applications in chemical industry is the production of

chlorine with the chlor-alkali-electrolysis process. Components of interest:

Hydrogen and chlorine

• Major chemicals mainly used in fertilizer manufacturing are made in the Haber-

Bosch Process (Ammonia Production) and

• the Ostwald Process (Nitric Acid Production). More applications can be found in:

• Sulfuric Acid production,

• Ethylene production in Cracking Process,

• Recycling Gas - Hydrogen in Hydrocarbons and

• Air Separation and Hydrogen production In all of these applications continuous gas

analysis is required

• for process control, quality assurance and safety measurement.

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• In Iron and Steel production the major operations related to gas analysis are:

• Coke production

• Sinter process

• Iron production, especially top gas analysis

• Steel production

• and Steel Refining

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• What have you learned from this module?

• ABB gas analyzers have been installed in almost every industry - throughout the

world

• The application for gas analysis goes far beyond emission monitoring

• Process measurements are successfully installed in many industries, like

chemical/petrochemical industry, power plants, iron and steel or cement production

and waste incinerators

• ABB gas analyzers helping our customers to run their processes more efficiently,

saving energy and cost.

• Have you understood everything so far? If so, click the button to "continue".

Otherwise, if you„d like to repeat this topic, click "No".

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