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Software CEM is a patented, model-based, predictive emissions moniotoring system that provides a certifiable, cost effective solution as an alternative to costly, hardware-based CEMS. It utilizes powerful analytic models of the process and emission sources with real-time validation to provide highly accurate, predictive emission values at half the cost of traditional sensors. Learn how Software CEMS can be applied in a variety of industries to realize cost savings.
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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
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Software-Based Continuous Emissions Monitoring Systems for Reporting and Optimization Joseph Miller - Director of Environmental Solutions
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Hardware Schematics
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
NOX Wet
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Increasing Cost of Hardware Validation
Hardware CEM (analyzers and system) accuracy is verified daily due to equipment drift and aging Verification is performed with costly Calibration Gas
Typical 2% certified gas is used Uptime as required by agencies is >95%
Continuous routine maintenance is required for operation Yearly sustainable operating costs are more then double that of Software CEM
Hardware CEM Linearity is verified quarterly via a Calibration Gas Audit (CGA) Verification is performed with multiple Calibration Gases that are
different than the gases used for Daily Cal-Check gas 3 level (low, mid, & high range) gases are used for linearity 1% Protocol gas is used
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Challenges and Pitfalls of Hardware CEMS
Copyright © 2009 Pavilion Technologies All rights reserved
Skilled maintenance labor required Sustained routine maintenance
Hazardous materials Calibration Gas storage Toxic condensation removal
High installation costs Real estate requirements Stack access High power demands
Heated sample lines Climate controlled environments
Consumable costs incurred Calibration Gas consumption Hardware rebuild kits
Analyzers Probes Pumps
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
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Software CEMs / Predictive Emissions Monitoring
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Software CEM®
A patented, model-based, Predictive Emission Monitoring System (PEMS) that meets USEPA 40CFR Part75; Subpart E as an “Alternative Monitoring System” and Performance Specification 16 (PS-16) Cost effective solution powered by Pavilion8™ software platform
Provides highly reliable and accurate continuous emissions monitoring Rockwell Software is an active expert in technical support to
regulatory agencies worldwide Patented & 1st introduced in 1993 Over 450 global installations Multiple units per site
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Software CEM® Design
Software CEM uses a nonlinear hybrid modeling methodology Models can be empirical, 1st Principles based or a combination of
both. Pavilion8 is platform independent Pavilion8 interfaces to all major DCSs, PLCs, and historians
Works with any reporting system Have interfaced with software developed in-house by end users
Pavilion8 OPC interface makes this especially easy by allowing users to interface with our Software CEM technology without the need to modify source code for over 1000 applications
Software CEM data can be used with/by any record keeping and reporting package
Users can receive training to perform their own maintenance if they choose
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
The Pavilion8 Software CEM® Solution
Consists of an emission model that reflects the relationship between process operations and ambient conditions to emissions.
A patented, sensor validation system to ensure the accuracy of the predicted emissions data.
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Sensor List 1. Delta P Air Inlet 2. Compressor Inlet pressure (air inlet) 3. Compressor Inlet temperature (air inlet) 4. Compressor discharge pressure 5. Compressor discharge temperature 6. Gas Generator exhaust temperature 7. Variable Guide Vanes Position (if equipped) 8. Gas Generator Speed 9. Power Turbine Speed 10. Load 11. Gas Fuel Flow 12. Water Augmentation (if equipped) 13. Inlet Misting (if equipped)
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Standard GT Sensor List
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Sensors used: Ammonia Feed Rate SCR Delta Temperature SCR Delta Pressure Inlet NOx
Standard SCR Sensors
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Standard Boiler Sensors Sample of Sensors used • Ambient Pressure • Temperature • Relative Humidity • Induced/Forced Draft Fan • Primary Air Damper (fixed or variable) • Economizer • Secondary Economizer (if equipped) • FGR (if equipped) • Stack Damper • Wet Stack 02 Monitors (if equipped) • Fuel Flow Monitor • Gas Fuel Composition • Individually controlled burners (if equipped)
We are able to model Low/Ultra Low NOx burners
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Other Sensors
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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Software CEM® vs. Hardware CEM Validation
Software CEM sensor validation routine is equivalent to the daily Cal-gas Check for hardware CEMS Software CEM validates sensors once per minute versus hardware
CEM once every 24 hours 1440 times to 1 in a 24 hour period.
Uptime as required by agencies is >95% Hardware CEM targets 95% (98% for Part 75) Software CEM is near 100%
Software CEM Model Validation routine is equivalent to the CGA for a hardware CEM Software CEM validates the model once per day versus hardware
CEM once per every calendar quarter 90 times to 1 in a calendar quarter
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Software CEM® Design Sensor Validation Model
This graph represents the real sensor (fuel flow) and the reconstructed value.
This graph illustrates the other sensor values being used during the reconstruction period
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Software CEM® RATA Accuracy within + 7.5% Scale
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Sensor Status Validation Tracking
Real-time Maintenance support tool
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Data Acquisition System (DAS) Reporting Providing Reports to the State and US EPA
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
DAS System - Operator Overview
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DAS System - Reports Generator
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DAS System – Report Grouping
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DAS System – Trending
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DAS System - Security
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Primary Applications
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Software CEM® Applications - Industry Independent
Sources Boilers Turbines Duct Burners Dryers Thermal Oxidizers Reciprocating Engines Regenerative Thermal Oxidizers Process Heaters Olefin Furnaces Marine Deisels
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Fuel Types Natural Gas No. 2 Fuel Oil Other Fuel Oils Refinery Gas (Tail, Sour, Syn.. Etc.) Process Gas Combined Fuels Bio Mass (Landfill, Algae, Digester.. Etc.)
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Boilers (Steam & Power) Fuels
Natural Gas Light and heavy oils
Gaseous Emissions Modeling
NOx/O2/CO/CO2 1st Principles
SO2 (for heavy oil) Potential APC equipment adders
Scrubber for heavy oil SCR and SNCR
Additional reporting values – NH3/NOx reduction Vertical Markets
Power/District Heating/Process Steam Generation/P&P/Ethanol/CMM/CPG Chemical and Petrochemical Refineries
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Turbines
Fuels Natural Gas Light Oil
Gaseous Emissions Modeling
NOx/O2/CO/CO2
Potential APC equipment adders SCR Additional reporting values – NH3/NOx reduction
Vertical Markets Power/District Heating/Process Steam Generation (HRSGs) Chemical and Petrochemical Refineries
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Duct Burners (HRSGs)
Fuels Natural Gas
Gaseous Emissions Modeling
CO/O2/CO2
Potential APC equipment adders SCR Additional reporting values – NH3/NOx reduction
Vertical Markets Process Steam Generation (HRSGs) Chemical and Petrochemical Refineries
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Land/Marine Based Diesels
Fuels Natural Gas Light and heavy oils
Gaseous Emissions Modeling
NOx/O2/CO/CO2 1st Principles
SO2 (for heavy oil) Potential APC equipment adders
Scrubbers for heavy oil ESP for heavy oil SCR and SNCR
Additional reporting values – NH3/NOx reduction Vertical Markets
Power/District Heating/Process Steam Generation/P&P/Ethanol/CMM/CPG Chemical and Petrochemical Refineries
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Software CEM® Lower Total Cost of Ownership
(1) Hardware CEM HWCEM $130,000.00 (NOX, O2, CO)
Shelter $ 30,000.00 (New) Access(add if needed) $ - Installation $30,000.00 * Pre-RATA $ 5,000.00 RATA $ 8,000.00 Total Initial Install $199,000.00 Daily Gas $10,000.00 CGA Gas $ 6,000.00 RAA (RATA) $ 8,000.00 Power consumption $12,,000.00 Consumable Parts $ 8,000.00 Maintenance Labor $15,000.00 Total Annual Costs $ 59,,000.00 Hardware CEM $649,000.00 * Sample Line, Probe, Ground Bus, Electrical
(1) Software CEM SWCEM $100,000.00 License Included Engineering Included Installation (DoE) Included Validation Included Pre-RATA Included RATA $ 6,000.00 PS-16 Portable $ 7,000.00 Total Initial Install $113,000.00 Daily Gas $ 0.00 PS-16 Gas (Qrt’ly RAA) $ 400.00 RAA (RATA) $ 8,000.00 Power consumption $ 100.00 Consumable Parts $ 100.00 Total Annual Costs $ 8,600.00 Software CEM $199,000.00
Annual Recurring Costs
Hardware CEM and PS-16 compliant-Software CEM Lifecycle Cost Comparison
10 year Recurring
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Joseph Miller ([email protected]) Questions?