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

SICK process automation Industry overview Emission Power Waste Cement Pulp & paper Metal & steel Chemical Petrochem & refineries Oil & gas

SICK process automation Scopes Emission Analyser for a variety of process measurements Process Compact transmitters with 1 to 2 measuring components High-performance analysers with up to 4 measuring components Multi-component analysers > 4 measuring components Measuring devices for tunnel monitoring Tunnel Rugged measuring devices with 1 to 3 measuring components Measurement of air quality and visibility Early fire detection 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 3

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)

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

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

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

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

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

GM32: The extended In-Situ solution

Differential Optical Absorption Spectroscopy 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 Wave length Extinction SO2 NO NH3 NO2 <-- 190 nm --> 400 nm >>> DOAS Differential Optical Absorption Spectroscopy

GM32 - Optical System - Control Cycle Advantages: Automatic self test Basic,Pro and upon request Check of zero Basic,Pro and span Pro for 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

GM32 SCR De-NOx control

CCGT plants - CEMs

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

Application: CEMS for CCPP : Extractive Technology : In situ Technology Flow Gas FLOWSIC100 PowerCEMS100 CO, NOx, O2, option SO2, CO2 : SICK MAIHAK GmbH Power_CEMS forCCPP_en_2012_09 5

Minimum Requirements / Recommendations : 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 : SICK MAIHAK GmbH Power_CEMS forCCPP_en_2012_09 5

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

PowerCEMS 100 > 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. : SICK MAIHAK GmbH Power_CEMS forCCPP_en_2012_09 : Name (Date) 8

Best Solution: Flowsic100 > 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 : SICK MAIHAK GmbH Power_CEMS forCCPP_en_2012_09 : Name (Date) 8

Why is DEFOR better than Chemiluminescence ? > Continuous individual measurement of up to 3 components NO, NO2 and SO2 > No interference from background gases (H20 and CO2 show no absorption in the UV range) > Adjustment unit for calibration of DEFOR without using test gas > No Converter, No Ozone = less trouble : SICK MAIHAK GmbH Power_CEMS forCCPP_en_2012_09 11

: User-friendly analyzer system GMS800 Advantages : 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 : SICK MAIHAK GmbH Power_CEMS forCCPP_en_2012_09 11

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

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