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Emission Monitoring

Many years of experience world wide


combined with our knowledge and
know-how within gas analysis and system
integration make us able to offer the best
equipment for emission monitoring and
reporting. FLSmidths continuous emission
monitoring and reporting system can be
configured to be in compliance with any
legislative demand.

July 2008
FLSmidth - Emission Monitoring

CEM - Continuous Emission Monitoring


Application
During the last years, requirements for Continuos Emission
Monitoring has increased significantly in order to fulfill the
demands set by the local authorities. Due to an increasing
number of demands on protection of the environment, most
plants must now deal with even greater reductions on emission
values and the reporting of these. On the other hand, plants
are investing in CEM systems in order to burn waste, obtain
ISO 14000 certification and introduce a Green Protection as
a value driver.

Process objectives
The CEM system installed in the stack measures both the
concentration (in mg/m3 or ppm) and the total emission of
the various polluting gasses and dust. To report these data, a
conversion to standardised physical values must be calculated
in order to compare the data with emission limits set by the
enforced emission legislation. As some of the components
measured are very small in concentration, and the demand
for precision set by legislation is very strict, the demands for
high quality precision analysis with proven repeatability is
obligatory.
Two different technics are used for measurement: in-situ and
extractive.
In-situ measurement is a method where the analyser is
mounted directly on the stack, and the measurement is made
in the stack. The measurement is made at actual process
temperature, pressure, water content and dust concentrations.
Thus, the meaurement system must be able to operate under
these conditions, and the normalisation of the measurement
must be done externally.

Fig.1 On site installation with dust, flow and gas anlysers


The benefits of the CEM system are

Extractive measurement is a method where process gas is


extracted from the stack and transported to the gas analysis
system. It is normally done in fixed physical conditions and
is therefore not affected by changing process conditions. It
is able to handle high dust loads. To avoid wash out of gas
components, a heated sample system is used. Validation and
calibration can be done with a test gas allowing easy quality
assurance of the equipment.

Reduction of harmful emission gasses


Reporting of emission values
Reduction of fuel consumption through waste burning
Income on disposal fees through waste burning
Fulfilment of local emission legislation

Legal specifications from local authorities set up


requirements for the analytical components needed on
various configurations. Typical approved analytical technics
are specified together with a demand for e.g. sensitivity,
availability, calibration and validation methods.
Standardisation has been implemented in some countries/
regions; other areas have specified their own unique set of
rules. Our large international experience allows us to choose
a setup of instruments and measuring methods in compliance
with every one of these rules and in this way provide the most
beneficial solution. Our independency as supplier
gives us the freedom to choose and implement
the Best Available Technology (BAT). Being cement
process specialists, we have the advantage of being
able to combine the legal demands with production gains and
hereby pursuit a plant emission strategy.

FLSmidth - Emission Monitoring, rev. July 2008

Fig.2 Emission monitoring system placed on stack

CEM - Continuous Emission Monitoring


In-situ gas analysis by LASER
measurement principle

Sample probe for extractive gas


analysis. In-situ measurement for
dust, temperature and pressure

In-situ ultra sonic


flow measurement

Gas Monitoring Unit GASloq 1200


or multi component analyser type

Fig. 3 The configuration of the CEM equipment must reflect the legislation enforced by the local authorities or a specific permit
for a given plant. Demands on CEM systems can be limited to a dust monitor or to a complex system comprising of dust, flow,
pressure, temperature, gas analysis and data acquisition system. In determining the best configuration for a specific country or
plant, FLSmidth can provide the most beneficial solution as we are not dependent on any specific sub-supplier.
Equipment objectives
The choice of configuration type (in-situ or extractive) is very
complex and is often determined by limitations in the legislation
or by the given process conditions in the stack.
FLSmidths default configuration consists of a combination of
the two techniques. For dust, flow, temperature and pressure,
we normally use in-situ measurements. For gas analysis
components, we use a heated extractive system.

Many years of experience world wide combined with our


knowledge and experience within gas analysis and system
integration make us able to offer the best analysis equipment
for each emission monitoring and reporting task. Every solution
is based on an evaluation of the individual plant in cooperation
with the customer and in many cases the local environmental
authorities. For more information on the exact configuration of
your emission reporting system, please contact any FLSmidth
representative or visit our home page at www.flsmidth.com/gas

The reporting system must be in accordance with the legislation


and able to produce the requested reports. Security of data is
a major concern. FLSmidth is capable of supplying a standalone PC solution or a total integration into a plant central
control system.
Gas components to be measured on stack
Requested Components (RC) as specified in the legislation
and Utility Components (UC), which are needed to perform
the conversion of data into normal values.
Conventional fuels (coal, oil, gas etc.)
Requested Components (RC): CO, NOX, SO2, Dust
Utility Components (UC): O2, H2O, flow, temperature, pressure,
calculation/ reporting
Waste fuels
Requested Components (RC): CO, NOX, SO2, THC, HF, HCl
Utility Components (UC): O2, H2O, dust, flow, temperature,
pressure and calculation/reporting

Fig. 4 Continuous Emission and Moniitoring (CEM) and


reporting system. Optional incorporation with the ECS/StackGuide system packages available for full plant integration and
safety replication of data.

FLSmidth - Emission Monitoring, rev. July 2008

Flow and Dust


Choosing the right dust or flow monitor
Dust and flow monitors are often contained in the emission
equipment in order to complete the entire emission package.
Choosing the right dust or flow monitor for a specific
application depends on several factors: the dust concentration,

the stack dimensions, the placement of the stack, the water


content and the requested accuracy. Our competent team
of project and sales engineers has extensive experience in
finding the best suited instruments for the specific needs of
our customers.

Durag D-R 216


filter monitor
Durag D-R 290
dust monitor
Durag D-R 300-40
dust monitor

Durag D-R 800


dust monitor
Durag D-R 290, D-R 30040 and D-R 800 are high
accuracy dust monitors for
measuring of dust emission
in dry gases in stacks with

smaller as well as larger


diameters.
They
are
especially applicable for
measurements of low
dust concentrations in
mg/m3 and are used for
emission and filter control.
Typical applications sites
are district heating plants,
waste incinerators, power
plants and cement plants.

Durag D-FW 230/231


is a triboelectric filter
monitor for efficiency
monitoring after the
bag filter.

Durag F-904-20 is a dust


monitor especially designed
for analysis of wet flue gas
with a temperature below
dew point. F-904-20 is
ideal for measurement
of low as well as high
dust concentrations. It
determines the amount
of radiation a sample
absorbs when exposed to
a radioactive source.
The measuring principle Durag F-904-20
with the beta gauge is an dust monitor for wet gases
absolute measurement in
mg/m3. Thus, the gravimetric calibration, essential for all
optical dust monitors, is not needed for the F-904-20.
Typical applications are power plants and waste incineration
plants.

Durag D-FL 100


flow monitor
Durag D-FL 100 and
D-FL 200 are volume
flow meters. D-FL 100
operates according to
the differential pressure
principle and is ideal for flow
measurement downstream
of dry/semi dry exhaust gas
cleaning. D-FL 200 employs
ultrasonic measuring in
exhaust gas below dew
point, e.g. downstream

Durag D-FW 230/231


filter monitor

Durag D-R 216 is an


optical filter monitor
used for filter control
after the bag filter
and the electrostatic
precipitator.

Durag D-FL 200


flow monitor
of the wet scrubbers, in
waste incinerators, etc.
D-FL 200 is ideal for flow
measurement in dry/noncondensing as well as wet/
condensing flue gas.

FLSmidth - Emission Monitoring, rev. July 2008

Durag D-RX 250


is a single rod
measurement probe
for
simultaneous
measurement
of
Durag D-RX 250
dust concentration
combined dust and flow monitor
[mg/Nm], volume
flow [Nm/h], temperature [C] and absolute pressure
[hPa]. D-RX 250 is often used at smaller power stations
and district heating plants.

Systems
Analyser Units
Our gas analysis systems can be supplied with any brand of
high quality extractive analysers. The extractive method can be
hot/cold or wet/dry or any combination of the two. Typically
the IR, UV, FID, paramagnetic or electrochemical measuring
principles are used. FLSmidth has the knowledge and capability
to integrate customer preferences and/or serve as a consultant
as we are an independent system integrator.
GASloq
FLSmidth supplies extractive
gas analysis systems GASloq
600, 800 or 1200. The GASloq
systems are designed to
sample, condition and analyse
process gas or emission gas and
to present the measurement
result in a display and to the
plant control system.

The types of analysers mostly used by FLSmidth are Emerson


Process Management, ABB, Mess- & Analysentechnik
and Siemens. Dependent on the combination of gases to
be measured, dust concentrations in the process gas and
investment conditions, the best suitable analyser unit is chosen.
Our range of analysers are able to measure up to 60 different
gases, e.g. O2, CO, CO2, NO, NO2, SO2 and TOC.

sampled through a sample probe and a sample hose to the


conditioning unit in the GASloq gas analysis system where the
gas is conditioned and analysed.
All operation and supervision of the gas analysis system is
performed from the cabinet through the HMI. The PLC controls
the function of all connected instruments and components.
Together with the GASloq gas analysis systems, a wide range
of accessories can be delivered.

Extractive
gas
analysis
means, contrary to in-situ
gas analysis, that a sample is
taken continuously from the
process for analysis. The gas is

Calibration gases, parts for start-up, wear and spare parts,


commissioning and service contracts are among the most used
accessories delivered together with a complete gas analysis
solution.

ABB ACF-NT - Multi Component


Gas Analysis System
Analysis system for analysis of O2, CO,
H2O, SO2, NO, NO2, HCl, NH3, HF and
TOC. The ABB ACF-NT is an extractive
heated analysis system consisting of a
heated probe, a heated hose and an
analysis system.

GASloq CUBE
Together with the GASloq gas analysis systems, a wide range
of accessories can be delivered. If it is not possible to install the
GASloq system indoors, the use of a GASloq CUBE site shelter
is a good solution.

The ACF-NT is based on the FTIR measuring


principle and can be configured for
analysis of many gases in one instrument.
It is also possible to deselect some of the
above measurements. The ACF-NT can be
upgraded without change of hardware.
As emission measurement system, the
ACF-NT analysis system is noted for being able to measure all
the gas parameters to be registered from waste incineration
plants according to Directive 2000/76/EC of the European
Parliament. The instrument is TV approved according to 17.
BimSchV with only 2 calibrations per year and the availability
factor according to the TV certification is 98%.
Typical applications are among others Cement kilns, Municipal
waste incinerators and power plants.

The GASloq CUBE


is delivered as a
plug-and-play
installation with
ideal conditions
for
operation,
commis sioning
and
service/
maintenance as
the instruments
are placed in
dust free and
temperature
stable conditions
and are mounted
on the wall for
easy mainteance.
A GASloq CUBE provides large reductions in the overall
installation cost and will also prove most beneficial in the
pursuit of better run factor for the analysing equipment.

FLSmidth - Emission Monitoring, rev. July 2008

ECS/StackGuide - Emission Reporting


ECS/StackGuide
ECS/StackGuide is FLSmidths cost-efficient product to guarantee all emission monitoring and reporting requirements.
Combustion related plants such as cement and waste
incinerations plants all over the world are facing a growing
amount of rules and demands by various authorities on how
to report their emissions from their production. The term
CEMS (Continuous Emission Monitoring System) is applied
for a complex of requirements for system configuration,
monitoring roles, data validation methods and reporting types
in the emission reporting demand.
ECS/StackGuide is a CEMS package to accomplish these
requirements. The main benefits of this package are:


Guarantee for complete fulfilment of emission legislation


requirements anywhere in the world
Easy customisation to any special requirements for
central, local or plant authorities
Improvement of emission statistics by early warning of
plant operators about any upcoming emission violation

If the raw data exists in ECS control systems, ECS/StackGuide


supports the redundancy of the control system to collect the
maximum available data from the servers. In addition, a catchup function in ECS/StackGuide makes sure that if the data
collection is interrupted, the missing data will be collected
automatically in order to avoid data gps in the CEMS database.
Lack of data in the CEMS database may result in penalties.
Safe data storage
All the retrieved raw data are kept intact. This means that the
data validation of the raw values will only produce new data
instead of deleting or manipulating the raw data. Keeping the
raw data unchanged is not only crucial for the legislations,
but also enables the user to simulate tighter emission
requirements to forecast future investments in the process.
The data storage media of ECS/StackGuide is the industrystandard MS-SQL database system.
Customised reports
Depending on the legislation, the requirements for what needs
to be reported will determine the overall content and format of
the report. Typically however, daily, weekly, monthly, quarterly
and yearly reports must be provided. The reports are in most
cases in a customised layout with plant identification logos,
filing references and formats. Specially customised reports
may be added.
Dependent on the countrys legislation, the customer may
need to produce an overview of e.g. emitted amount of NOX
in a given month for tax purposes or the like. For the use in
e.g. green accounts, in calculations of energy consumption or
of energy efficiency, etc. customer adjustments are available

Cost-efficient solution
Traditionally, the CEMS solutions have been developed on a
highly plant-specific basis. In order to meet the demands for
data validation and monitoring roles, parts of the solutions
have traditionally been implemented at the PLC level with
programming intensive effort resulting in working, but quite
complex solutions that are difficult to maintain in long-term.
Other parts of the solution are traditionally implemented as
special data retrieval and reporting system with customised
programming approaches.
ECS/StackGuide is the most professional and cost-efficient
CEMS application with many advantages some of which are
listed here:
Secured data retrieval

FLSmidth - Emission Monitoring, rev. July 2008

General features
Historical databases and data access
OPC data access
Dedicated reporting package
Built-in MS-Excel add-ins for report customisation
Advanced trending software
Data editing
Web access
Windows 2000, XP and 2003
Terminal server support for remote access
Service release and hotfix support
Realtime and historic emission control
Store data for years
Emission data
MS-SQL Server relational database
Advanced data validation methods
Data tournament for dual ECS control system sources
Catch up to retrieve lost data from down periods (by
use of the ECS solution)
Firewall between plant control and administrative
system

ECS/StackGuide - Emission Reporting


providing the customer with
exactly what he needs in terms
of report content and format.
Naturally, this customisation will
have no influence on the CEMS
data collection ability, quality or
system performance. Finally, all data
can be exported, allowing further
data processing possibilities.
Real-time monitoring
In the past, real-time emission values
have not been available to the plant
operators due to the difficult task of calculating
the Continuous Emission Monitoring System (CEMS)
data in the report format required by legislation. The
CEMS reports were history to the operators, and the
emission reporting systems were regarded as necessary
only to satisfy the demands by authorities. Since realtime emission values were not accessible, operators
were only able to base their actions on the parameters
presented as raw values from the various analysers
in the stack. As the normalisation of the raw
values has various effects on the reported
values, it was considered of great advantage Foreign SCADA system
and importance to develop an environment
or other data sources
in which the plant operators could be able
to monitor the current emission conditions
that would eventually be reported to the
authorities.
The development of ECS/StackGuide presents a solution
to this need as ECS/StackGuide provides a situation in
which the plant operators can monitor the current values
of the emission in the current production. The values available
are not only the traditional raw values, but the normalised
and validated values for the current statistical period that
are eventually going to affect the emission report. Thus, the
operators will be able to act proactive and take corrective
actions in the process to minimise the emission violations
before critical limits are reached.
When seeing the real-time, normalised emission values it is
possible for the plant operator to operate the kiln and the
plant according to these results and to the Emission Limit
Values (ELV) for the plant. Continuously, the plant operator
may follow the emission values and ensure that the values are
kept below the ELV. The early warnings and trends for emission
values render it possible to avoid daily ELV exceeding.

ECS Server 1

ECS Server 2

Gas Monitoring
Unit 1200

the operator to document the reason of the failure. The


operator comments can then later be included in the emission
reporting.
Continuously, all real-time and historic data are logged for
reports and data retrieval. This renders it possible at any time
to retrieve data from the system for new reports, export of
data or other tasks that might be of interest for the plant or
the authorities.
To fulfil future demands, real-time data will be a natural part
of all future emission reporting systems. Real-time is already
a standard in ECS/StackGuide which is easily integrated into
FLSmidth Automations ECS control system. However, ECS/
StackGuide may also be integrated with other control systems
as on-line imported and displayed in the existing control
system environment.

In the case of events such as analyser failure, the real-time


monitoring system will detect the condition and enable

FLSmidth - Emission Monitoring, rev. July 2008

About Us
Company profile
FLSmidth A/S forms part of the FLSmidth Group, an
international group supplying process know-how and total
lines of machinery, mainly to the cement and minerals
industry.

This way, FLSmidth A/S has a sound basis for supplying


customers with the technological know-how needed, and
we are able to deliver the best suitable product for the job
and the customer.

FLSmidth A/S has more than 30 years of experience within


gas analysis and detection and has grown into one of the
most important companies within measurement and control
of polluting gasses in primarily the cement and combustion
industries.

Power plants, waste incineration plants, refineries, district


heating stations, cement plants as well as many companies
within process industries are among FLSmidth A/Ss regular
customers, and over the years our technical department has
created a confident relationship to technical advisors both
at home and abroad.

Our success is based on a dedicated and competent


workforce as well as reliable business relationships both
with customers and suppliers. We believe in punctual
deliveries at the agreed cost and in accordance with the
promised specifications. We will not be dependent on one
single supplier and thus, we are general agents for suppliers
such as ABB, Crowcon, Durag, Emerson and NEO Monitors.

Our team of service engineers are fully trained in projecting


and servicing the highly complex instruments and analysis
systems. A complete solution includes pre-projecting,
delivery including documentation, commissioning, and
training as well as maintenance on site.

TESTING

SERVICE

PRODUCTION

ENGINEERING

Addresses

www.flsmidth.com/gas
FLSmidth - Emission Monitoring, rev. July 2008

Main office

Copenhagen office

FLSmidth A/S
Klostermarken 6
DK-9550 Mariager
Tel.: +45 70102277
Fax.: +45 70102288

FLSmidth A/S
Hffdingsvej 34
DK-2500 Valby
Tel.: +45 70102277
Fax.: +45 70102288

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