Software-Based Continuous Emissions Monitoring Systems for Reporting and Optimization

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

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Software-Based Continuous Emissions Monitoring Systems for Reporting and Optimization Joseph Miller - Director of Environmental Solutions


Hardware Schematics


NOX Wet


Increasing Cost of Hardware Validation

Hardware CEM (analyzers and system) accuracy is verified daily due to equipment drift and aging Verification is performed with costly Calibration Gas

Typical 2% certified gas is used Uptime as required by agencies is >95%

Continuous routine maintenance is required for operation Yearly sustainable operating costs are more then double that of Software CEM

Hardware CEM Linearity is verified quarterly via a Calibration Gas Audit (CGA) Verification is performed with multiple Calibration Gases that are

different than the gases used for Daily Cal-Check gas 3 level (low, mid, & high range) gases are used for linearity 1% Protocol gas is used


Challenges and Pitfalls of Hardware CEMS

Copyright © 2009 Pavilion Technologies All rights reserved

Skilled maintenance labor required Sustained routine maintenance

Hazardous materials Calibration Gas storage Toxic condensation removal

High installation costs Real estate requirements Stack access High power demands

Heated sample lines Climate controlled environments

Consumable costs incurred Calibration Gas consumption Hardware rebuild kits

Analyzers Probes Pumps


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Software CEMs / Predictive Emissions Monitoring


Software CEM®

A patented, model-based, Predictive Emission Monitoring System (PEMS) that meets USEPA 40CFR Part75; Subpart E as an “Alternative Monitoring System” and Performance Specification 16 (PS-16) Cost effective solution powered by Pavilion8™ software platform

Provides highly reliable and accurate continuous emissions monitoring Rockwell Software is an active expert in technical support to

regulatory agencies worldwide Patented & 1st introduced in 1993 Over 450 global installations Multiple units per site


Software CEM® Design

Software CEM uses a nonlinear hybrid modeling methodology Models can be empirical, 1st Principles based or a combination of

both. Pavilion8 is platform independent Pavilion8 interfaces to all major DCSs, PLCs, and historians

Works with any reporting system Have interfaced with software developed in-house by end users

Pavilion8 OPC interface makes this especially easy by allowing users to interface with our Software CEM technology without the need to modify source code for over 1000 applications

Software CEM data can be used with/by any record keeping and reporting package

Users can receive training to perform their own maintenance if they choose


The Pavilion8 Software CEM® Solution

Consists of an emission model that reflects the relationship between process operations and ambient conditions to emissions.

A patented, sensor validation system to ensure the accuracy of the predicted emissions data.


Sensor List 1. Delta P Air Inlet 2. Compressor Inlet pressure (air inlet) 3. Compressor Inlet temperature (air inlet) 4. Compressor discharge pressure 5. Compressor discharge temperature 6. Gas Generator exhaust temperature 7. Variable Guide Vanes Position (if equipped) 8. Gas Generator Speed 9. Power Turbine Speed 10. Load 11. Gas Fuel Flow 12. Water Augmentation (if equipped) 13. Inlet Misting (if equipped)

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Standard GT Sensor List


Sensors used: Ammonia Feed Rate SCR Delta Temperature SCR Delta Pressure Inlet NOx

Standard SCR Sensors


Standard Boiler Sensors Sample of Sensors used • Ambient Pressure • Temperature • Relative Humidity • Induced/Forced Draft Fan • Primary Air Damper (fixed or variable) • Economizer • Secondary Economizer (if equipped) • FGR (if equipped) • Stack Damper • Wet Stack 02 Monitors (if equipped) • Fuel Flow Monitor • Gas Fuel Composition • Individually controlled burners (if equipped)

We are able to model Low/Ultra Low NOx burners


Other Sensors

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Software CEM® vs. Hardware CEM Validation

Software CEM sensor validation routine is equivalent to the daily Cal-gas Check for hardware CEMS Software CEM validates sensors once per minute versus hardware

CEM once every 24 hours 1440 times to 1 in a 24 hour period.

Uptime as required by agencies is >95% Hardware CEM targets 95% (98% for Part 75) Software CEM is near 100%

Software CEM Model Validation routine is equivalent to the CGA for a hardware CEM Software CEM validates the model once per day versus hardware

CEM once per every calendar quarter 90 times to 1 in a calendar quarter


Software CEM® Design Sensor Validation Model

This graph represents the real sensor (fuel flow) and the reconstructed value.

This graph illustrates the other sensor values being used during the reconstruction period


Software CEM® RATA Accuracy within + 7.5% Scale


Sensor Status Validation Tracking

Real-time Maintenance support tool


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Data Acquisition System (DAS) Reporting Providing Reports to the State and US EPA


DAS System - Operator Overview


DAS System - Reports Generator

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DAS System – Report Grouping

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DAS System – Trending

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DAS System - Security

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Primary Applications


Software CEM® Applications - Industry Independent

Sources Boilers Turbines Duct Burners Dryers Thermal Oxidizers Reciprocating Engines Regenerative Thermal Oxidizers Process Heaters Olefin Furnaces Marine Deisels

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Fuel Types Natural Gas No. 2 Fuel Oil Other Fuel Oils Refinery Gas (Tail, Sour, Syn.. Etc.) Process Gas Combined Fuels Bio Mass (Landfill, Algae, Digester.. Etc.)


Boilers (Steam & Power) Fuels

Natural Gas Light and heavy oils

Gaseous Emissions Modeling

NOx/O2/CO/CO2 1st Principles

SO2 (for heavy oil) Potential APC equipment adders

Scrubber for heavy oil SCR and SNCR

Additional reporting values – NH3/NOx reduction Vertical Markets

Power/District Heating/Process Steam Generation/P&P/Ethanol/CMM/CPG Chemical and Petrochemical Refineries


Turbines

Fuels Natural Gas Light Oil


NOx/O2/CO/CO2

Potential APC equipment adders SCR Additional reporting values – NH3/NOx reduction

Vertical Markets Power/District Heating/Process Steam Generation (HRSGs) Chemical and Petrochemical Refineries

http://www.blimpbase.com/storage/wp-content/uploads/2009/08/turbine.jpg

http://images.google.com/imgres?imgurl=http://img.alibaba.com/photo/10842796/2_X_Ge_Unipak_Gas_Turbine_Power_Plant.jpg&imgrefurl=http://www.alibaba.com/product/johnmccullagh-10842796-10643058/2_X_Ge_Unipak_Gas_Turbine_Power_Plant.html&usg=__IMjHy-g6UYTifaX6Gk6XJQEVYJw=&h=480&w=640&sz=47&hl=en&start=11&um=1&tbnid=jof1UJBWOuPQYM:&tbnh=103&tbnw=137&prev=/images?q=ge+gas+turbine+pictures&hl=en&sa=X&um=1


Duct Burners (HRSGs)

Fuels Natural Gas


CO/O2/CO2

Potential APC equipment adders SCR Additional reporting values – NH3/NOx reduction

Vertical Markets Process Steam Generation (HRSGs) Chemical and Petrochemical Refineries

http://www.rentechboilers.com/products/heat_recovery.php


Land/Marine Based Diesels

Fuels Natural Gas Light and heavy oils


NOx/O2/CO/CO2 1st Principles

SO2 (for heavy oil) Potential APC equipment adders

Scrubbers for heavy oil ESP for heavy oil SCR and SNCR

Additional reporting values – NH3/NOx reduction Vertical Markets

Power/District Heating/Process Steam Generation/P&P/Ethanol/CMM/CPG Chemical and Petrochemical Refineries

http://www.emma-maersk.com/gallery/photo/engine_2.jpg

http://www.outboardmotoroilblog.com/wp-content/uploads/2009/03/biggest-2-stroke-engine.jpg


Software CEM® Lower Total Cost of Ownership

(1) Hardware CEM HWCEM $130,000.00 (NOX, O2, CO)

Shelter $ 30,000.00 (New) Access(add if needed) $ - Installation $30,000.00 * Pre-RATA $ 5,000.00 RATA $ 8,000.00 Total Initial Install $199,000.00 Daily Gas $10,000.00 CGA Gas $ 6,000.00 RAA (RATA) $ 8,000.00 Power consumption $12,,000.00 Consumable Parts $ 8,000.00 Maintenance Labor $15,000.00 Total Annual Costs $ 59,,000.00 Hardware CEM $649,000.00 * Sample Line, Probe, Ground Bus, Electrical

(1) Software CEM SWCEM $100,000.00 License Included Engineering Included Installation (DoE) Included Validation Included Pre-RATA Included RATA $ 6,000.00 PS-16 Portable $ 7,000.00 Total Initial Install $113,000.00 Daily Gas $ 0.00 PS-16 Gas (Qrt’ly RAA) $ 400.00 RAA (RATA) $ 8,000.00 Power consumption $ 100.00 Consumable Parts $ 100.00 Total Annual Costs $ 8,600.00 Software CEM $199,000.00

Annual Recurring Costs

Hardware CEM and PS-16 compliant-Software CEM Lifecycle Cost Comparison

10 year Recurring


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Meet Your Everyday Technical Needs Online & Phone Support Training Services OnSite Services Repair Services

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Software-Based Continuous Emissions Monitoring Systems for Reporting and Optimization