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Outline of presentation
CEMS Definition
Benefits of CEMS
Components of CEMS
Methods and Options for Source emission monitoring
Location of installation of CEMS
In-situ CEMS
Extractive CEMS PM CEMS Technology Selection Matrix
PM CEMS Calibration issues
CEMS Options for Gaseous pollutants
Available International quality certification of CEMS
Minimum Quality Control Requirement
Options for continuous Velocity measurement technologies
Parameter-wise Regulatory requirement of CEMS in 17 categories
of industries and HWI
Proposed steps in implementation of CEMS in regulatory
framework
Benefits of CEMS
COMPONENTS OF A CEMS
Sample Collection sampling device
Interface Sample conditioning & transportation
wherever required
Analyzer Specific to pollutants, generates an
output signal proportional to the concentration
Calibration devices Analyzer control system,
calibration gases, recording etc
Data Acquisition Data logging system record
electrical signals in defined number of channels
Data Handling System Pick, calculate, record,
transfer the data in report form to desired
destination
Additionally Flow Rate Monitor (where
applicable)Senses flue gas velocity, used to
Manual
Stack Emission
Monitoring
Portable / Reference
Methods
CEMS
Extractive
Dilution
In Stack
Cold Dry
In-situ
Hot Wet
Out of Stack
PD
Point Type
Cross Stack
Predictive
EMS
Secondly It should be at the plane 500 mm above the Isokinetic testing Port, so,
that the reference monitoring methods are not disturbed
The installation should have logistic support like easy approach for
calibration, maintenance etc.
In-situ CEMS
Transfer Interface
Analyzer
Extractive CEMS
Extractive PM CEMS
Scatter-light Wet
Principle is same as dry but the gas is extracted and heated to
vaporise the water droplets and moisture.
Counter Tube
4-20mA
STATI
C-14 Source
Total Flow
Vacuum
Pump
Filter-Adapter
with Bypass
Sample Cooler with
Controller
Automatic Drain
Supply Reel
Exhaust
Filter Advance
Stepping Motor
Take-up
Reel
Stack
Dilution Gas
Venturi Nozzle
Units of
Measured Value
DC Tribo
g/s,
kg/hr
AC Tribo
mg/m3,
g/s, kg/hr
Light Scatter
Opacity
mg/m3
mg/m3
Light
Scintillation
mg/m3
Extractive
Light Scatter
BAM
mg/m3
mg/m3
Velocity Monitor
Required
Duct < 1m
Diameter
Duct >1m to 4m
Diameter
Duct > 4m
Diameter
Electrostatic
Precipitator
***
Stack Gas
Temperature >
5000C
Wet Scrubber or
Water Droplet
<700C
Large particles
> 20um
***
***
****
Varying gas
velocity
***
**
* Primary Wet Stack, ** Worked on slowly varying velocity, *** ESP/Wet scrubber, *** Meas.upto 300 mg/m3
Time period
of sampling
Normalized
Concentration of PM
Emission(iso-kinetic
sampling)**
Factory Operating
Condition (Production
capacity (%); APCD
on/off)
Yi (mg/Nm3)
Recommended for 15 points calibration at different load factor to ensure
linearity in detection range
At least 6 times if load variation is not possible
Supporting parameters like velocity, % Moisture, CO2 and O2 makes the system
full proof for regulatory purposes.
Sr. No.
Iso-kinetic
reading
CEMS reading
1
2
3
4
5
6
Iso-kinetic reading
0
25.2
26.1
24.1
28.3
21.1
18.1
0
44.2
53.4
46
59.8
38.1
36.8
70
y = 1.9821x - 0.7055
R = 0.9714
60
50
40
30
20
10
0
0
-10
10
15
CEMS reading
20
25
30
Blow Back
To distantly located
analyzers thro Heated
sample line
Walk-in
shelter
Analyzers
Condenser
Pump
SO2
NOx
CO
Drain
CO2
Output Signal to
DAS
Blow Back
To distantly located
analyzer - heated line
Walk-in
shelter
Heated
Analyzer
SO2
Heated
Pump
NOx
CO
CO2
Output Signal to
DAS
Dilution Probe
Optical Components
DOAS
Differential
Optical
Absorption
Spectroskopy
DOAS
DOAS
Differential
Differential
Optical
Optical
Absorption
Absorption
Spectroskopy
Spectroskopy
IR source
Sample gas
Detector
front
rear
absorption volume
Sample gas
Measuring side
Reference side
Pressure-balancing
capillary
N2
Membrane capacitor
Synchronous
motor
Measuring
amplifier
N2
Modulation
wheel
A/D
converter
N2
Microprocessor
Analog outputs
Display
RS232C Interface
IR source
Sample gas
Detector
front
rear
absorption volume
Sample gas
Measuring side
N2
Reference side
N2
Pressure-balancing
capillary
Membrane capacitor
Synchronous
motor
N2
Gear
motor
Modulation
wheel
N2
Measuring
amplifier
A/D
converter
N2
Microprocessor
Analog outputs
Display
RS232C Interface
USA
QAL 1 (EN)
(Quality assurance level 1)
QAL 2 & QAL 3 (EN)
Performance Standard
MACT
(Maximum Achievable Control
Technology); this is an objective
oriented quality certification
applicable to US only
TUV (Germany)
(Technical watch-over
Association) a Product
standard
MCERTS (UK)
(Monitoring Certification
Schemes) a Product standard
PS-1 to PS 11
(USEPA) It is a performance
Standard
Flow
Direction
Ultrasonic
Transit
time
difference
between upstream and
downstream
signal
is
proportional to the velocity
of flue gas.
Microprocessor
Evaluation Unit
Temperature
Measuring
Transducer
(optional)
Det 2
Det 1
Minimum QC Requirements
d) Daily drift checking
For opacity monitors daily drift is limited to +/-2% opacity
For PMs the daily drift is limited to +/-3% of span
For flow monitors the daily drift is limited to +/-3% of span
Daily records must be kept and adjustments shall be made if the drift is
greater than 10% of the calibration gas value
Type
Irregular
Flow
Max Flue
Gas
Temperatu
re
Wet stack
Low speed
High
Speed
Calibration
1
2
3
Thermal
anemometer
Bi-directional
ultrasonic
Infrared
correlation
Up to 550C
Up to 550C
200 300oC
(model specific)
450 C - 850 C
(model specific)
Up to 1000oC
X
X
X (minimum 5 m/s)
1 m/s 50m/s
Up to 40 m/s
(model specific)
Factory+Site
Factory+Site
Factory+Site 3
Factory+Site
Factory+Site
1 m/s 50m/s
Pressure Transmitter (PT) and Temperature Transmitter (TT) are not installed with a
Thermal Anemometer as it directly measures Mass Flow which is usually the required
quantity. However, for the purpose of ETS in Type 2 CEMS configuration, Volumetric Flow
is required and hence PT and TT are necessary to calculate density and convert mass flow
calculated by the anemometer to volumetric flow.
Can be accounted for by using multiple probes/sensors
Calibration depends on physical properties (thermal conductivity, specific heat) of the
gas whose flow is to be measured. Thus variation in properties of stack gas from factory
calibrated values can result in inaccurate measurement.
HARDWARE SPECIFICATIONS
Industry should select a vendor fulfilling the following requirements:
Specifications
PM CEMS Device
User defined
10 mg/Nm3 or less
Flow Meter
User Defined
1 m/s (minimum detectable limit)
1 minute
1 minute
<2% of measurement range
Drift
1 minute
1 minute
< 5% of measurement
range
< 1% per month
Power supply
220 +/- 10 V at 50 Hz
Data Availability
Measurement range
Instrument
detectable concentration
Data acquisition
Data transmission
Deviation in the raw reading
17 Categories of Industry, their emission standards and probable options for CEMS
SN
Industries
Aluminium Smelting
Raw Material Handling
Calcinations
Green Anode Shop
Anode Bake Oven
Pot room
PM 150
PM 250
CO 1% (Max)
PM 150
PM 50
Total Fluoride 0.3 Kg/MT of Al
PM 150
Total Fluoride 2.8 Kg/MT of Al
for Soderberg Technology
Total Fluoride 0.8 kg/t for Pre-baked
Technology
For incinerator
PM 50
SO2 200
CO 100
TOC 20
PCDDs /F 0.2ng TEQ/NM3 (existing)
PCDDs /F 0.1ng TEQ/NM3 (New
commissioned after July 2009)
Metals 1.5
In situ PM CEMS
NDIR for CO
FTIR for CO and F
DOAS for all
In-situ PM CEMS
Preferably Extractive PM CEMS
NDIR for CO
IR GFC, FTIR, DOAS for multi-gas
analysis
FID for HC (TOC)
PCDDs, Metal not possible by
CEMS
17 Categories of Industry, their emission standards and probable options for CEMS
SN
Industries
PM 100
PM 75
In-situ PM CEMS
7
8
SO2 200
HCl (Mist) 35
NH3 30
Cl2 15
Captive Incinerator
PM 50
SO2 200
HCl (Mist) 50
CO 100
TOC 20
PCDDs /F 0.1ng TEQ/NM3
Metals 1.5
Fermentation (Distillery)
Fertiliser (Phosphate)
Boiler Standard
PM 150
Total Fluoride 25
PM 150
PM 150 (Normal Operation); PM 450 (Oxygen Lancing)
PM 150
PM 50
CO 3 Kg/T coke
PM 150
UV Fluorescence,
FTIR, DOAS
In situ PM CEMS
IR GFC, FTIR, DOAS TLD, PAS for
multi-gas analysis
FID for TOC
PCDDs, Metal not possible by CEMS
17 Categories of Industry, their emission standards and probable options for CEMS
SN
10
11
Industries
Pollutants Emission Limits
Leather Processing Tanneries
Boilers Standard
Oil Refinery
Furnace, Boiler and captive power plant Polutants Before 2008
Gas based
SO2
50
NOX
350
PM
10
CO
150
Ni + V
5
H2S
150
After 2008
50
BAM for PM
250
IR GFC, FTIR, DOAS TLD, PAS
5
100
5
150
1700
450
100
200
5
150
850
350
50
150
5
150
FCC Regenerator
Hydro
Others
SO2
NOX
500
400
PM
100
CO
400
Ni + V
% Opac.
H2S
NOX
CO
30
15
350
150
1700
450
350 (N)
100
50 (N)
400
300 (N)
2 (N)
2
30
10 (N)
250
100
SRU
In situ PM CEMS
IR GFC, FTIR, DOAS TLD, PAS for multi-gas analysis
or individual technology specific to pollutants
17 Categories of Industry, their emission standards and probable options for CEMS
SN
12
Industries
Pesticide
13
14
Petrochemical
15
16
Sugar
Thermal Power Plants
Less than 210 MW
More than 210 MW
PM 350
PM 150 In situ PM CEMS
In situ PM CEMS
In situ PM CEMS
17 Categories of Industry, their emission standards and probable options for CEMS
SN Industries
PM 100
PM 75
SO2 1370 (Existing);1250 (New)
Acid Mist and Sulphur Trioxide
90 (Existing); 70 (New)
SO2 1250 (Existing) ;950 (New)
Acid Mist and Sulphur Trioxide
70 (Existing); 50 (New)
In situ PM CEMS
FTIR, DOAS
Particulate Matter
1600
1200
150
In situ PM CEMS
Steam Generation
less than 2
2 to less than 10
10 to less than 15
15 and above
Particulate Matter
1200
800
600
150
All above concentrations are subject to
12 % CO2 correction
Notes:
Wherever load based standards are notified Flow/Velocity Monitor is mandatory
O2, CO2 monitoring is essential where the standards are to be corrected for.
CO2 monitoring is a complementary part of monitoring if extractive dilution system is
selected.
mg/Nm3
50
50
200
100
50
20
4
400
30
30
30
30
24 hours
30
30
30
0.1 ngETQ/Nm3
0.05
0.05
0.50
8
2
2
2
hours
hours
hours
hours
Notes:
i.All monitored values shall be corrected to 11 % oxygen on dry basis.
ii.The CO2 concentration in tail gas shall not be less than 7%.
iii.In case, halogenated organic waste is less than 1% by weight in input waste, all the facilities in twin chamber
incinerators shall be designed to achieve a minimum temperature of 950oC in secondary combustion chamber and with a
gas residence time in secondary combustion chamber not less than 2 (two) seconds.
iv.In case halogenated organic waste is more than 1% by weight in input waste, waste shall be incinerated only in twin
chamber incinerators and all the facilities shall be designed to achieve a minimum temperature of 1100oC in secondary
combustion chamber with a gas residence time in secondary combustion chamber not less than 2 (two seconds).
v.Incineration plants shall be operated (combustion chambers) with such temperature, retention time and turbulence, as to
achieve Total Organic Carbon (TOC) content in the slag and bottom ashes less than 3%, or their loss on ignition is less than
5% of the dry weight].
Thank You