Latest Equipment Innovations for LCPD

1. Latest Equipment Innovations for LCPD Colin Blackmore/Mark Davidson SICK (UK) Ltd AQE Conference March 2013

2. Emission Power Waste Cement Metal & steel Pulp & paper Process Chemical Oil & gas Petrochem & refineries SICK process automationIndustry overview

3. SICK process automationScopes Process Tunnel Emission Analyser for a variety of process measurements Measuring devices for tunnel monitoring Measuring devices and system solutions for continuous emission monitoring • Entire product range for all requirements • In situ and extractive measurement technologies • Solutions for all industries and legal regulations • Compact transmitters with 1 to 2 measuring components • High-performance analysers with up to 4 measuring components • Multi-component analysers > 4 measuring components • Rugged measuring devices with 1 to 3 measuring components • Measurement of air quality and visibility • Early fire detection

4. Equipment for LCPD • Process gas analysers • DeNOx process monitoring and control equipment • Continuous Emission Monitors - General Gas Analyser systems for Coal, Gas, Oil Power Stations • CCGT Plant and measurement of low levels of NOx • Mercury monitoring in Coal-fired Power Stations (separate Workshop presentation)

5. Gas preheater Air preheater EP Boiler FGD FGD plant Ammonia Water DeNOx reactor EP Limestone Slag Coal Air gypsum Ashes DeNOx Plant

6. Application SCR DeNOx Plant • Why do we want to measure? • With the help of a catalyst, NO and NH3 react to N2 and water: • 4 NO + 4 NH3 + O2 4 N2 + 6 H2O • NO measurement is important for the process control: • a) raw gas before catalyst : to calculate the NH3 injection rate • based on the “NO load” • b) check catalyst efficiency and NH3-trim 1

7. Application SCR DeNOx Plant • Technical Data: • Measuring Range: • before SCR: up to 1,500ppm NO depending on burner technology • after SCR : up to 100ppm NO depending on local regulation • gas temperature: 340 ... 420°C • high dust : typically 15g/m3 • duct size: typically 5m (1.5 .... >6m) 1

8. Extractive Technology Challenges • Multiple Sample Probes with graded entry holes to try and balance the sample flow across large ducts and ensure accurate measurements • Standard extractive CEM system with Filtration, Cooling, Sample Switching Problems - very high dust burden - high maintenance load on Sample Systems - unreliable systems

10. In-situ Technology Challenges • Cross duct not practical due to high Dust Burden, extinction of signal in large ducts • High temperature application • Sick Solution – extract sample and measure with small path length • Orientate probe so as to avoid large particles being captured • If 15m/sec flow achieved then remaining dust stays in suspension • Dust shows as general extinction, which can be calibrated out

15. GM32: The extended In-Situ solution

16. Extinction SO2 NO NH3 NO2 Wave length <-- 190 nm --> 400 nm GM32 - optimized measuring value evaluation Absorption curves of SO2, NO, NO2 and NH3 • Evaluation principle DOAS with sophisticated algorithms • No influence of dust, droplets, humidity and other gases • In-situ >>> delay free • High and stable accuracy for high and low measuring ranges >>> DOAS Differential Optical Absorption Spectroscopy

17. GM32 - Optical System - Control Cycle • Advantages: • Automatic self test Basic,Proand upon request • Check of zero Basic,Pro and span Profor each component. • No test gases required. • Compliance to EN 14181, EN 15267-3 • QAL3 zero & span values Pro • TÜV approval Pro • Interval adjustable Basic,Pro • Pro Version with filter wheel • Basic version without ~ • no difference in quality of measurement

18. GM32SCR De-NOx control

19. CCGT plants - CEMs

20. : SICK MAIHAK GmbH Power_CEMS forCCPP_en_2012_09 5 Power Combustion air Power Gas Generator Generator Flow Steam turbine Gas turbine Cooling air Heat recovery steam generator Steam Data Acquisition system Cem View or MEAC2000 FLOW Stack CO NOx,, O2,

21. : SICK MAIHAK GmbH Power_CEMS forCCPP_en_2012_09 5 : Extractive Technology: In situ Technology PowerCEMS100 Gas CO, NOx, O2, option SO2, CO2 FLOWSIC100 Flow

22. : SICK MAIHAK GmbH Power_CEMS forCCPP_en_2012_09 5 :Gas components Nitrogen monoxide (NO) + Nitrogen dioxide (NO2) = “NOx as NO2” IR not low enough ranges for NO Carbon monoxide (CO) - Oxygen (O2), correction to reference conditions : Option - Sulfur dioxide (SO2), Carbon dioxide (CO2) : Flow measurement : Data acquisition system according to the EN or US EPA requirements

23. : SICK MAIHAK GmbH Power_CEMS forCCPP_en_2012_09 : Name (Date) 6 Best Solution: PowerCEMS 100 MAC800 compact system PowerCEMS 100 GMS 830 and 831 analyzer modules sample gas cooler Control unit BCU

24. : SICK MAIHAK GmbH Power_CEMS forCCPP_en_2012_09 : Name (Date) 8 > Certified according to EN 15267-2 and EN 15267-3 to be used as AMS for CCPP > Compliant to EPA Part 60 and Part 75 CEMS requirements for gas fired power plants > Single central operating unit (BCU) for easy operation > No NOx converter for better measurement accuracy and lower cost of consumables > Low level CO monitoring done by field proven UNOR best accuracy of any NDIR on the market. > Compact, suitable for wall mounting > Interface to DAS or DCS via Modbus or OPC or hard wire, adaptable to customer’s requirements.

25. : SICK MAIHAK GmbH Power_CEMS forCCPP_en_2012_09 : Name (Date) 8 >Flue gas temperatures up to 450°C > High accuracy even at gas velocities near zero > Corrosion resistant Titanium transducers as standard > Representative measurement using cross-stack version

26. : SICK MAIHAK GmbH Power_CEMS forCCPP_en_2012_09 11 > Adjustment unit for calibration of DEFOR without using test gas > No Converter, No Ozone = less trouble

27. : SICK MAIHAK GmbH Power_CEMS forCCPP_en_2012_09 11 :No need to use a NOx converter, change converter cartridges : User-friendly analyzer system : Designed for lower maintenance: simple single-point linearization, excellent thermal stability : With the UVRAS principle low ranges of NO, NO2, SO2 (0 - 25 ppm) can be accurately and individually measured. : Using the NDIR principle to measure CO in low ppm ranges (20 ppm) can be achieved. New Mounting of the NDIR bench on rubber supports reduces vibration sensitivity. : Using the paramagnetic measuring principle to analyze O2 : Latest cold dry CEMS analyzer technology UNOR & DEFOR with an excellent value for CCPP

28. Emission monitoringApplication-specific fully configurable system Central control unit Connecting additional networks using standard interfaces Dust, volume flow (in situ) High-grade analyser modules and components All required gas components (extractive)(SO2, NO, NO2, NH3, HF, CO, CO2, CH4, HCl,N2O, H2O...)

29. Thank you for your attention.