Source Emission Monitoring Technologies

Presented by: Zaheerullah Mohammed

Brief introduction onAmbient Air Quality Monitoring Systems

Ambient air quality capability:-GACS Arabia has extensive experience in ambient air qualitymonitoring systems; we have installed various types of installationsfrom fixed permanent stations, mobile station on van, truck and towtrailers. We are the only Saudi Company in the market which does allof the installation and commissioning works locally in Saudi Arabia, wehave vast experience in ambient air quality applications engineering.We also own and operate ambient air quality station which is in fullcompliance with US EPA 40CFR part 58 standards, we can domonitoring projects or rent the station to your project.

Ambient Air Quality Systems & Monitoring Capabilities:-

GACS Integrated Ambient Air Systems

GACS Integrated Ambient Air Stations

Source Emission Systems & Testing Capabilities:-

Source emission monitoring:-GACS Arabia is among the very few systems integrators to build source emissionmonitoring systems locally in Saudi Arabia, and we also provide testing servicesfor stack testing, RATA testing, CEMs and PEM’s verification and setup projects.We also own and operate a fleet of mobile CEM station’s which is in fullcompliance with US EPA 40CFR part 60 + 75 requirements for the criteriaparameters such as; SO2, H2S, NOx, CO, CO2, THC, VOC, Particulate.GACS owns and operates an extensive selection of equipment to handle any sizeof source testing program, whether stack or fugitive emission sources. In supportof sampling collection, GACS has an in-house laboratory offering quickturnaround times of unique sampling parameters.

GACS Integrated Source Monitoring Systems

CEMSContinuous Emission Monitoring Systems

Source Emission Monitoring Technologies

What is Source Emission

Continuous emission monitoring systems (CEMS) were historically used as atool to monitor flue gas for oxygen, carbon monoxide and carbon dioxide toprovide information for combustion control in industrial settings. They arecurrently used as a means to comply with air emission standards such as theUnited States Environmental Protection Agency's Acid Rain Program, EuropeanUnion Standards, other country specific federal/national emission programs, orstate permitted emission standards. Facilities employ the use of CEMS tocontinuously collect, record and report the required emissions data.

Primary Markets, estimated 1095 Stacks in Total and Increasing

Power Plants 30% of the MarketOil & Gas 20% of the MarketDesalination & Utilities 15% of the MarketPetrochemicals 20% of the MarketCement Plants 15% of the Market

Secondary Markets

Level II Industries Private and IWPP PlantsChemical PlantsPrivate Small Scale Cement Industries & Production Facilities

International Market Standards:-

• US: EPA• Europe: TUV, MCERTS, EN etc..,• China: Chinese Pattern, and so on..,• Russia: Russian GOST-R

Saudi Arabia:-

• Two (2) EPA’s: PME & The Royal Commission• Corporate Standards: Saudi Aramco & SABIC• Urban Standards: Riyadh MODON, ADA

Source Sampling (Stack Testing) Services

Our testing services are in compliance with

US EPA 40CFR Part 60, 63 & 75

STACK EMISSION METHODS & REFERENCES

Gases Reference Method– US EPA CFR 40 Part 60 TOC/THC Reference Method– US EPA method 25A

Particulate Reference Method– US EPA method 5, & 17

Saudi Aramco Reference Method – SAES-A-102

Royal Commission Reference Method – RCER 2010

Difference between Part 60, 63 vs 75

Periodic Audit Requirements

Part 60, 63 Systems• Daily drift – all analyzers• Quarterly CGAs – gas analyzer• Quarterly calibration error – opacity monitor• Quarterly leak check – DP type stack flow monitor• Annual RATA – all analyzers

Part 75 systems• Daily drift check – all analyzers• Daily interference check – stack flow monitor• Quarterly linearity check – gas analyzer• Quarterly leak check – DP type stack flow monitor• Quarterly stack flow-to-load analysis – stack flow

monitor• Semiannual/annual RATA & bias check – all

analyzers• Annual fuel flowmeter accuracy check – Part 75• Appendix D reporting systems

Criteria Pollutants for CEMsSL Parameter Description of Pollutant US EPA Method

01 Particulate Matter

Atmospheric particulate matter – also known as particulate matter (PM) or particulates – is microscopic solid or liquid matter suspended in the Earth's atmosphere. The term aerosol commonly refers to the particulate/air mixture, as opposed to the particulate matter alone.Sources of particulate matter can be man-made or natural. They have impacts on climate and precipitation that adversely affect human health.

US EPA Method 5

02 Sulfur dioxide (SO2)

Sulfur dioxide is the product of the burning of sulfur or of burning materials that contain sulfur:To aid combustion, liquefied sulfur (140–150 °C) is sprayed through an atomizing nozzle to generate fine drops of sulfur with a large surface area. The reaction is exothermic, and the combustion produces temperatures of 1000–1600 °C.

US EPA Method 6C

Criteria Pollutants for CEMs

SL Parameter Description of Pollutant US EPA Method

03Carbon Monoxide

CO

Carbon monoxide is an odorless, colorless gas. It is a chemical asphyxiate like hydrogen sulphide. At low levels of exposure, it causes headaches, dizziness, disorientation, nausea, and fatigue. The effects of CO exposure can vary greatly from person to person depending on age, overall health, and the exposure concentration and duration. Carbon monoxide can come from a variety of sources in the workplace including aged or poorly maintained combustion devices (boilers, furnaces, etc.), and vehicle exhaust from attached garages, nearby roads, or parking areas.

US EPA Method 10

04Carbon dioxide

CO2

Carbon dioxide is an important greenhouse gas. Burning of carbon-based fuels since the industrial revolution has rapidly increased its concentration in the atmosphere, leading to global warming. It is also a major cause of ocean acidification since it dissolves in water to form carbonic acid.

US EPA Method 3A

Criteria Pollutants for CEMs

SL Parameter Description of Pollutant US EPA Method

05Oxygen

O2

Oxygen is required for sustaining life, and at only slightly reduced or increased levels can cause impairment. Reduced levels of Oxygen are very unlikely in office space environments, and values deviating from 20.9 % would only be expected due to changes in elevation.

US EPA Method 3A

06Nitric Oxide

NOx

Thermal NOx formation, which is highly temperature dependent, is recognized as the most relevant source when combusting natural gas. Fuel NOx tends to dominate during the combustion of fuels, such as coal, which have a significant nitrogen content, particularly when burned in combustors designed to minimize thermal NOx. The contribution of prompt NOx is normally considered negligible. A fourth source, called feed NOx is associated with the combustion of nitrogen present in the feed material of cement rotary kilns, at between 300°and 800 °C, where it is also a minor contributor.

US EPA Method 7E

Types of Approved CEMs in Market

Extractive CEMs Dilution CEMs In-Situ CEMsHot Gas CEMs

(Extractive)

The standard CEM systemconsists of a sampleprobe, filter, sample line(umbilical), gasconditioningsystem, calibration gassystem, and a series ofgas analyzers which reflectthe parameters beingmonitored

Dilution systems sample atlow flow rates or dilute thesample prior to analysiswhich results in lowerwater vapor andparticulate matter content.Conditioning may beperformed at the port or atthe analyzer

In situ CEMS are systemswhere the analyzer isphysically located in thestack or duct. The effluentgas is measured in situ as itflows through a samplinglocation placed in the stackor duct. Two types of in situmeasurements arepossible: point (in-stack)and path (cross-stack).

Typical to standardExtractive CEMs, thesystem consists of sampleprobe, filter, sample lineand only change is therewill be no sampleconditioner. This is becauseof measuring at hightemperature levels tocapture specifichydrocarbons

Very Common, cost effectiveand widely acceptable andwidely used technology

Application specific, suitablefor high acid, SO2 and dustystacks

Expensive to install, verydifficult to maintain (due tolimited access to system)

Application specific, mostcommonly used for glass andincineration applications

Suppliers:-Teledyne, Dr. Foedisch etc..,

Suppliers:-Teledyne API

Suppliers:-Many suppliers

Suppliers:-Dr. Foedisch

Type’s of CEMs Installed by our CompanyExtractive CEMs – Most common application

US EPA Standards CEMsAcceptable by Local Standards

* Single Gas Analyzers Extractive CEMs

European Standards CEMsAcceptable by Local Standards * Multi-Gas Extractive CEMs

Source Sampling (Stack Testing) Services

Complete Design- Heated probe- Heated Sample Line- Sample Conditioner- Acid Filter- Flow Panel- Calibrator - Gas Analyzers:SO2, NOx, CO, CO2 & O2

- DAS System- Calibration Procedures- Compliance to Methods- Operation- Reporting

System Design is in compliance with US EPA 40CFR Part 60, 63 & 75

Type’s of known systems in CEMs NetworkExtractive CEMs, Widely Preferred Method

US EPA & European Standards CEMsAcceptable by Local Standards

Source Sampling (Stack Testing) Services

Extractive Continuous Emission Monitoring System

Type’s of CEMs Installed by our CompanyDilution CEMs – Site Specific

US EPA Standards CEMsAcceptable by Local Standards

US EPA Standards CEMsAcceptable by Local Standards

Type’s of known systems in CEMs NetworkIn-Situ CEMs

US EPA & European Standards CEMsAcceptable by Local Standards

Difficult to Maintain and calibrate, since system is installed on the

stack

Type’s of known systems in SEC NetworkHot Gas Extractive CEMs

European Standards CEMsAcceptable by Local Standards

Measuring principle:

CO, NO, NO2, SO2, HCl, HF, NH3, H2O, CO2, N2O, CH4: infrared absorption (dual wavelength method respectively gas filter correlation)O2: ZrO2-cell

Smallest measuring ranges:

CO: 0 ... 75 mg/m³NO: 0 ... 200 mg/m3

NO2: 0 ... 50 mg/m3

SO2: 0 ... 75 mg/m3

HCl: 0 ... 15 mg/m3

HF: 0 ... 20 mg/m³NH3: 0 ... 10 mg/m3

H2O: 0 ... 40 Vol%CO2: 0 ... 25 Vol%N2O: 0 ... 50 mg/m³CH4: 0 ... 50 mg/m³O2: 0 ... 25 Vol%

PEMSPredictive Emission Monitoring Systems

What is PEMs?• PEMS (Predictive Emissions Monitoring System) is an acceptable alternate

to CEMS (Continuous Emission Monitoring System).

• Approved by US EPA helping in monitoring of emissions.

• Accurate and reliable online measurements of CO, NOx, SO2, O2

• Predictions calculated by a mathematical model:

– Based on actual furnace test data

– Verified on 6-monthly basis against RATA Tests

– Prediction errors <7% required

• Generate and report real-time predictions of the emissions from stacks.

Emission Monitoring Installations (PEMS Vs CEMS)

PEMS System ArchitecturePredictive Emission Monitoring System

CEMS InstallationContinuous Emission Monitoring

PEMS Technology Overview

Neural Net

Adaptive

C P

MFuzzy Logic

Calculations

10*349304

1454

LD

dxSj

Non-linear

Inferential

PEMS At A Glance

PEMS Model Generation and Validation

RATA (Relative Accuracy Test Audit) Results Statistic RM Analyzer

Measured NOx Values

SS Predicted NOx Values

Mean of Absolute Differences

ABS (RM – SS)

97.5% Confidence Interval (CC)

% Relative Accuracy

Average 81.7 81.6 1.7 0.0644 1.8% Std Deviation 5.9 6.0 1.3

Sr.No. Time Predicted Nox Actual Nox Deviation

1 17:30 108 107 -0.9

2 17:31 106.6 109 2.2

3 17:32 107.5 110 2.3

4 17:33 108 110 1.8

5 17:34 107.6 110 2.2

6 17:35 105.1 111 5.3

7 17:40 105.7 109 3.0

8 17:41 107.6 110 2.2

9 17:42 107.7 110 2.1

10 17:43 107.6 111 3.1

11 17:44 106.6 110 3.1

Average 109.7 107.1 2.4

Prediction Accuracy

Web Report and Dashboards

Summary: Advantages of PEMS• PEMS, reveals the science behind stack Emission

Comparison of the cost CEMS versus PEMS

0

20000

40000

60000

80000

100000

120000

140000

160000

1 2 3 4 5 6 7 8 9 10

Years

$U

S CEMS

PEMS

• Generic numbers based on CEMS cost

model Software as supported by US EPA.

• Even 20-40 % higher maintenance costs are

reported for CEMS.

• Low Installment & maintenance cost

• Independent from Automation System at sites

• Flexible reporting and customizations

• Compliant to Environmental Regulations

• An effective data validation tool if CEMS exists.

• No spares/special skills needed

• Links to any data source (DCS, PLC, Historian or other)

• Integrates with any relational database and ERP system

• Provides web based access and web based reporting

• Provides e-mail or SMS based alerts and intelligent alarming when emissions exceed limits

• Provides knowledge management system and data archiving for compliance with regulations

• Fully flexible system open to expansion

Source Sampling (Stack Testing) Services

Emission TestingPermit Compliance TestingPeriodic Monitoring

CEMS & PEMsMonitoring (CEMS, PEMs) TestingPEMS & CEMS Performance TestsRelative Accuracy Test Audits (RATA)Quarterly Audits / Certifications, CGAs, Linearity

Control Equipment TestingSpecification and Efficiency TestingControl Equipment Optimization

Custom Emissions TestingEmission Inventory TestingFugitive Emission TestingAir Toxics Screening StudiesSpecial Testing Protocols

Capabilities:Our testing staff's practical experience and technical understanding of all aspects of source testing allows us to determine the correct test method for each specific projects pollutants of concern. Our experience includes:

Source Sampling/Stack TestingPerformance, Pre-tests, and EPA Compliance Tests

Source (Stack) testing capability, CEMs & PEMs

Special Applications, Glass Manufacturing high temp stacks

Source Sampling (Stack Testing) Services

• 3rd Party Stack testing for particulate emissions

• Labor Intensive and Involves lot of methods calculations

• US EPA methods 1,2,3,4 & 5 for Mass PM, PM17, PM10 and Orsat sampling system

• US EPA Method 201A/B for PM10 & PM2.5

Test Method Definitions – PEMs Baseline Data

• PEMs requires considerable amount of baseline data to be used for developing good model of PEMs

• GACS Deploys CEMs station to collect baseline data for number of days – to develop a good model for PEMs developer

• The CEMs data is then used to develop PEMs Predictive models, by recording “Process Inputs”

• The CEMs data is in compliance with US EPA and Saudi Aramco standards

Source Sampling (Stack Testing) Services

Our testing services are in compliance with

US EPA 40CFR Part 60, 63 & 75

Source Sampling (Stack Testing) Services

Our testing services are in compliance with

US EPA 40CFR Part 60, 63 & 75

Source Sampling (RATA Testing) Services

Relative Accuracy Test Audit Using Instrumental Reference Methods

Fugitive Emissions Monitoring

Types

1. Sniffing (Only program that can quantify leaking sources on your equipment)

2. Infrared camera(Detect leaking sources in a qualitative way)

Sniffing

Camera

Monitoring Standards

1. European Standards EN 15446 and2. US EPA Method 21

Leak Detection And Repair Program (LDAR)

Identification of faulty equipment, Leak Detection,

Repair Management of Data

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