• Like
  • Save
Software-Based Continuous Emissions Monitoring Systems for Reporting and Optimization
Upcoming SlideShare
Loading in...5
×
 

Software-Based Continuous Emissions Monitoring Systems for Reporting and Optimization

on

  • 204 views

Software CEM is a patented, model-based, predictive emissions moniotoring system that provides a certifiable, cost effective solution as an alternative to costly, hardware-based CEMS. It utilizes ...

Software CEM is a patented, model-based, predictive emissions moniotoring system that provides a certifiable, cost effective solution as an alternative to costly, hardware-based CEMS. It utilizes powerful analytic models of the process and emission sources with real-time validation to provide highly accurate, predictive emission values at half the cost of traditional sensors. Learn how Software CEMS can be applied in a variety of industries to realize cost savings.

Statistics

Views

Total Views
204
Views on SlideShare
204
Embed Views
0

Actions

Likes
0
Downloads
33
Comments
0

0 Embeds 0

No embeds

Accessibility

Categories

Upload Details

Uploaded via as Adobe PDF

Usage Rights

© All Rights Reserved

Report content

Flagged as inappropriate Flag as inappropriate
Flag as inappropriate

Select your reason for flagging this presentation as inappropriate.

Cancel
  • Full Name Full Name Comment goes here.
    Are you sure you want to
    Your message goes here
    Processing…
Post Comment
Edit your comment

    Software-Based Continuous Emissions Monitoring Systems for Reporting and Optimization Software-Based Continuous Emissions Monitoring Systems for Reporting and Optimization Presentation Transcript

    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION Software-Based Continuous Emissions Monitoring Systems for Reporting and Optimization Joseph Miller - Director of Environmental Solutions
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Hardware Schematics
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. NOX Wet
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 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
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Challenges and Pitfalls of Hardware CEMS Copyright © 2009 Pavilion  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
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION Software CEMs / Predictive Emissions Monitoring
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 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
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 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
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 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.
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 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) 6 10 1 7 3 2 4 8 9 11 5 4 Standard GT Sensor List
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Sensors used: Ammonia Feed Rate SCR Delta Temperature SCR Delta Pressure Inlet NOx Standard SCR Sensors
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 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
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Other Sensors 13
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 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
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 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
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Software CEM® RATA Accuracy within + 7.5% Scale
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Sensor Status Validation Tracking Real-time Maintenance support tool
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION Data Acquisition System (DAS) Reporting Providing Reports to the State and US EPA
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. DAS System - Operator Overview
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. DAS System - Reports Generator 20
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. DAS System – Report Grouping 21
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. DAS System – Trending 22
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. DAS System - Security 23
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION Primary Applications
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Software CEM® Applications - Industry Independent Sources  Boilers  Turbines  Duct Burners  Dryers  Thermal Oxidizers  Reciprocating Engines  Regenerative Thermal Oxidizers  Process Heaters  Olefin Furnaces  Marine Deisels 25 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.)
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 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
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Turbines  Fuels  Natural Gas  Light Oil  Gaseous Emissions  Modeling  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
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Duct Burners (HRSGs)  Fuels  Natural Gas  Gaseous Emissions  Modeling  CO/O2/CO2  Potential APC equipment adders  SCR Additional reporting values – NH3/NOx reduction  Vertical Markets  Process Steam Generation (HRSGs)  Chemical and Petrochemical Refineries
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Land/Marine Based Diesels  Fuels  Natural Gas  Light and heavy oils  Gaseous Emissions  Modeling  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
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 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
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Services & Support Global Support. Local Address. Peace of Mind. Optimize Plant Assets Maximize Productivity Improve Financial Performance 80 Countries I 20 Languages I 6 Remote Support Centers I 10 Remanufacturing Depots I 9 Exchange Hubs I Average 13+ Years Experience Meet Your Everyday Technical Needs Online & Phone Support Training Services OnSite Services Repair Services Maximize Your Automation Investment MRO Asset Management Safety Services Energy Services Network & Security Services Managed Services
    • Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. www.rsteched.com Follow RSTechED on Facebook & Twitter. Connect with us on LinkedIn. PUBLIC INFORMATION Joseph Miller (Jdmiller1@ra.rockwell.com) Questions?