Analytical System Integration 2014 National Sales Meeting CGA: Continuous Gas Analyzers Analyzer or Application – The Question Bruce Herman - ABB Process Analytics Applied Controls Analytical System Integration 2014 National Sales Meeting

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ANALYZERS and APPLICATIONS   name where ABB sells CGA analyzers identify measuring points in the major applications select the right analyzer modules for applications

Agenda - Focus Points PRESENTATION FOCUS CGA – the product The Frankfurt Connection PRESENTATION FOCUS Product overview CGA: AO2000 CGA – the product Where do you find CGA Emissions Process APPLICATIONS POI (Points of Interest) DIALOG

ADVANCE OPTIMA 2000 Advance Optima – Reliable – Economic – Powerful Available for >15 years Powerful controller logic Class 1, Groups A,B,C,D, Div 2 Engineered

Continuous Gas Analyzers The Benefits of an Integrated Analyzer Concept CO CO2 NOx O2 Sample Handling

The most important area of applications for continuous gas analysis The most important area of applications for continuous gas analysis. Combustion processes can be found in many different industrial areas,

COMBUSTION PROCESSES 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.

CO2, H2O, N2 expected CO, HC, excess O2 incomplete combusion SO2, NOx Sulfur in fuel, N2 HCl, HF (Waste Incin) Hg, Particulates

Combustion efficiency Ideal combustion needs the right amount of oxygen. The oxygen value can be measured with a paramagnetic oxygen analyzer

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 Infrared for NO or alternatively ultra-violet photomete for NO and NO2, and laser analyzer for NH3 measurement.

Electrostatic precipitator The typical measuring component is carbon monoxide. Since CO is a flammable gas this measurement represents a safety measurement to avoid explosions. Infrared photometer.

Efficiency of the DeSOx process (desulfurization) The efficiency of the flue gas desulfurization is monitored by measurement of SO2 with Infrared. Alternately UV

The analyzer modules module name type typical Uras 26 NDIR photometer CO, CO2 Limas11 IR IR photometer CO,CO2, HCl Limas11 UV Limas 23 UV UV photometer NO, NOx Magnos 206 Paramagnetic, dumbbell O2 Magnos27 Heavy duty Caldos 27 Fast silicon sensor, TC H2 Caldos 25 Glass coated TC Chlorine NH3, SO2 FIDAS24 Flame ionization Fidas24 NMHC Non-meth HC, VOC ZO23 Zirconium dioxide O2 traces LS4000 Laser in-situ O2, CO, NH3 Oxygen cell chemical

ADVANCE OPTIMA 2000 ABB

Infrared Analyzer Module ABB Uras 26 Analyzer Modules Infrared Analyzer Module ABB Uras 26 CO CO2 SO2 NO CH4 ….

Uras26 Fulfils all the requirements for a lot of applications High Stability of zero and span point <1% drift per week High Sensitivity and smallest measuring ranges 0... 5 ppm CO2 High Selectivity smallest cross sensitivities optimized for the main applications Smallest detection limits < 20 ppb in a range of 0…5 ppm CO2 Suppressed range like 98…100 Vol% N2O High repeatability < 0,5% of the range Gas filled detector Membrane condensator Sample cell

Infrared, Principle CO SO2 N2 N2 CO SO2 N2 N2 N2 N2 CH4 NO ABB Uras 14 with 4 measured components and calibration cells N2 N2 CH4 p NO

Photometer Analyzer Modules ABB Limas 11-UV/IR NO SO2 NO2 NOx = NO + NO2

Limas 11-UV UV Simple adaption to the measuring task Various Measuring components: NO, NO2, SO2, H2S, CS2, COS, Cl2 and NH3 Low measuring ranges: 10 ppm NO, High Selectivity by best choice of - Interference and Gas Filter - Internal cross-sensitivity correction High Stability due to electrodeless source & unique 4-Beam Method Compact & economical solution for flammable, corrosive & toxic process gases Calibration without test gas bottles UV Meßkomponenten for die Verfahrenstechnik Niedrige Meßbereiche u.a. NO for Emissionmessungen Simple adaption to the measuring task

Limas 11 - Schematic Drawing Source FW1 CU IF GF FW2 M GF M CL3 BS D2 MC IM2 IM1 CL2 CL1 IR2 t D1 IR1 t IR - Source M Motor FW1 Filter wheel 1 FW2 Filter wheel 2 BS Beam splitter MC Measuring cuvette CL1,2,3 Collimator lenses D1,2 Detectors CU Calibration unit IF Interference filters GF Gas filters

Oxygen Analyzer Modules Magnos 206/27

Magnos – and Oxygen Technology Measurement in many applications Very few interferences Paramagnetic analyzer Measuring with a dumbbell Magnos27 Preferred for rugged applications No moving parts Measuring using thermal character Electrochemical Simple and economical Laser Diode In Situ NOT Paramagnetic

Magnos 206 Fast, Reliable Measurement Magneto-Mechanical Principle

Magnos27 Technology Paramagnetism of oxygen Two chamber system (measurement and reference) Measurement chamber is located in a magnetic field Temperature dependent resistors Measurement effect: Increased circulatory flow proportional to oxygen concentration measured through thermal conductivity.

Magnos 27 Robust Measuring Cell Thermomagnetic Principle Temperature dependent resistors ( Pt/Glass ... ca. 180 °C ) Bypass 60 °C Natural Gas Oil Coal

Oxygen Sensor Extended Range of Application, Suited for Stack Gas Monitoring PTFE Membrane Cathode ( Au ) Anode ( Pb ) - + Sample gas Electrolyte ( acidic )

LS4000 (TDL) Overview In situ tunable diode laser analyzer Measurement of oxygen (from 0-1 to 0-100Vol%) Stand-alone operation Compact & flameproof housing approved for use in hazardous areas (ATEX/IECEx/FM/CSA) (Class I, Div 1) Dynamic correction of changing process conditions

LS4000 Product overview

Caldos 25 Highly corrosion resistant glass coated resistors

Caldos 25 Independent of Ambient Pressure Sophisticated Measuring Cell Reference side Measuring side Bypass Glass- coated Glass 60 °C

Caldos 17 Fast Measurement

FID Analyzer Module FIDAS24 Analyzer Modules FID Analyzer Module FIDAS24

Fidas24 Key Features at a Glance New FID analyzer for Advance Optima and EasyLine series Continuous hydrocarbon and non-methane hydrocarbon analysis Large operating range: from low ppm to high vol% Easy to operate

AO2000 Series Analyzers

AO2000 Series Analyzers

AO2000 Series Analyzers

APPLICATIONS Power Generation CEMENT KILNS boilers furnaces heaters CEMS – 70% Power Generation CEMENT KILNS boilers furnaces heaters incinerators (if it burns…. ) PROCESS – 30% Cement Kilns CO2 in hydrocarbons CO in hydrogen H2 in Cl2 H2 in Hydrocarbons (nitrogen header..) O2 deficiency FID, incinerators, Hydrocarbon in water Special Emphasis NO and NO2 measurements for CEMS (LIMAS23 and LIMAS11) Landfill gas measurements CH4, CO2, O2 GREENHOUSE GAS CSA has a regulation Nitric Acid Plants NO/NO2 ratio issues Partner Partnering

Integrated Remote Control Full Access to Gas Analyzers Functionality You can start a remote session with the targeted analyzer immediately after right mouse click on the AO-icon

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