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Siemens Laser Analytics. Presentation Siemens Laser Analytics. Analyzers. Cost is very important from two perspectives Cost of investment Cost of owning Focus on process control for optimization of Energy Process quality Environment Critical issues for in-situ process analyzers

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siemens laser analytics
Siemens Laser Analytics
  • Presentation
  • Siemens Laser Analytics
analyzers
Analyzers
  • Cost is very important from two perspectives
    • Cost of investment
    • Cost of owning
  • Focus on process control for optimization of
    • Energy
    • Process quality
    • Environment
  • Critical issues for in-situ process analyzers
    • Performance
    • Quality
    • Availability
    • Real time reading
the lds 3000 analyser system

CU 3000

CD 3002

FC 3001

The LDS 3000 Analyser System

A central unit - CU 3000 - located in control room environment

  • up to 3 measuring point can be operated parallel with one central unit

Extreme robust sensors forming the process interface - CD 3002

The sensors are coupled to the analyser via a single hybrid cable containing fibre optics and copper wires - FC 3001

lds 3000 frequently asked questions
LDS 3000: Frequently Asked Questions
  • Mature, heavy-industry-proof sensor design?
    • LDS 3000: easy installation, highest performance, low maintenance
  • In-situ, no gas sampling?
    • LDS 3000: never in contact with the process gas!
  • Low maintenance?
    • LDS 3000: no moving parts, just cleaning of sensor lenses!
  • Fast response times?
    • LDS 3000: less than 2 s!
  • Problems with cross interference to other gases or dust load?
    • LDS 3000: high resolution single line absorption spectroscopy!
    • LDS 3000: signal available from 100 % - 0,3 % transmission!
lds 3000 heading new frontiers
LDS 3000: heading new frontiers
  • unique selling points of diode lasers:
    • In-situ line-of-sight measurement, no gas sampling
    • highest sensitivity and selectivity
    • fast response times down to 1 second
    • measurement feasible in high dust loads and complex gas mixtures
  • unique selling points of LDS 3000:
    • separation of analyser and process environment by using fibre optics and robust optical sensors
    • lifetime factory calibration by internal hands-off reference cell
    • measurement feasible in extrem and fast changing high dust loads
    • EEX ia as an option for operation in Ex zones
    • high competence in HT processes
customer c riteri a of an analyzer
Customer criteriaof an analyzer
  • Defined industrial interface
    • Installation, performance and maintenance
  • In-situ, no extractive sample lines
    • Never in contact with the gas
  • Minimum of maintenance
    • No moving parts
    • Cleaning lenses twice a year
  • Short response time
    • Less than 2 seconds
  • Interference free, in principle
    • Accurate and sensitive in rough environment
  • Compensated for dynamic dust load
    • From 100 % transmission to as low as 0,5 % transmission
applications
Applications
  • Combustion
    • Combustion optimization
    • DeNOx: financial incentive (MWI, Power Plants, Heavy Duty Vehicle)
    • Filter optimization
    • ESP safety
    • Emission
  • Metallurgy
    • Steel
    • Non-ferrous – Aluminium
      • Emission and process
  • Other
    • Chemical & refinery, today Ex certified
    • Glass
    • etc
major applications today
Major applications today
  • Components today NH3, O2/temp, HF/HCl and CO
  • Measure Ammonia in DeNOx
    • Power Plants, Heavy Duty, MWI
    • Measure Oxygen/temp in the combustion zones
    • MWI and Steel production (CO and CO2 )
  • Measure HF and HCl for filter optimization
    • Aluminum smelter and MWI
  • Measure HF and HCl for emission purpose
    • Aluminum smelter and MWI
  • Measure CO for ESP safety
    • Cement and HWI
the measurement system design10
The measurement system design
  • A central instrument unit is kept in a control room environment - CU 3000
    • Can handle 3 points simultaneously
  • An optical fiber cable, FC 3001, connects the central unit with the sensors
  • Extremely rugged sensor heads are used as the interface to the industrial process - CD 3002

Distance 10 - 1000 m

Transmitter

Receiver

typical nir spectra nh 3 h 2 o
Typical NIR Spectra: NH3/H2O

spectral region of laser scan

performance demand nh 3 slip at scr
Performance demand NH3 slip at SCR
  • Environment after SCR for NH3-slip
    • Range: 0 – 10 ppm
    • Accuracy: +/- 0,5 ppm
    • Response time: c:a 1 – 3 seconds or more
    • Path length: 3 – 10 m.
    • Dust load: < 15 g/Nm3
    • Temperature: < 650 °C
    • Flange: DN65/PN6 alt 150 lbs 4 “
    • Purge media: Fan alt instrument air
  • The demand.
    • To measure below 2 ppm of ammonia in high dutload.
scr on coal power plant
SCR on Coal Power Plant

App. 20 - 30 m.

App. 5 - 15 m.

one layer scr basic set up
One layer SCR basic set up
  • Inject NH3 in the raw gas
  • Minimize slip to the air pre heater
  • Monitor NH3 in situ
  • Optimizing cleaning cycles

NH3 + NOxÔ N2 + H2O

customers
Other NH3 installations

TotalELFAtofina

Rygerbergerdam – MWI

BBP

Alstom France & Italy

Yokogawa/TEPCO

Siemens

British Steel/Corrus

AMSA – MWI Italy

Shell

Detroit Diesel

Cummins

Volvo

Nissan Diesel

Bosch

Caterpillar

etc ....

Installations –

Västerås Power Plant

Amagerverk Power Plant

Noell – SCR supplier

Blach&Veach

China Steel

BBP – SCR supplier

Mobotec – SNCR supplier

Seward Plant, Reliant Energy

Cape Fear, CP&L

Roxboro 1 & 3, CP&L, sept. - 2002

Mayo, CP&L installation, jan. - 2003

Customers
spectroscopic temperature determination

T1

T2

T3

T1

T2

2

1

T3

1

2

Spectroscopic Temperature Determination
  • The analysis of the relative line strength of two close Oxygen lines in the same gas volume reveals the gas temperature
application combustion control in mwi
Application: Combustion Control in MWI

ZrO2

LDS3000

Results:

- approx. 70 s time delay

- better resolution of changes in the process conditions

(Data by courtesy of BBP Environment GmbH, 1998)

compensation of high dust loads
Compensation of High Dust Loads

O2 concentration in the process

Visibility conditions

performance demand o 2
Performance demand O2
  • Environment for O2
    • Range: 0 – 10 vol. %
    • Accuracy: +/- 0,1vol %
    • Response time: c:a 1 – 3 seconds or more
    • Path length: 3 – 10 m.
    • Dust load: < X g/Nm3
    • Temperature: < Y °C
    • Flange: DN65/PN6 alt 150 lbs 4 “
    • Purge media: N2 instrument air
siemens laser analytics application example municipal waste incinerator

Combustion control: stable power production, less corrosion, higher efficiency

DeNOx control: less corrosion, optimised NH3 consumption

Emission control

NH3-sensor

O2/temp-sensor

HCl and or NH3

-sensors

H2O-sensors

Filter control: minimised lime consumption, less corrosion

Siemens Laser Analytics – Application example Municipal Waste Incinerator
application optimisation of bag house filters
Application: Optimisation of Bag House Filters

Optimisation of gas cleaning by lime injection by fast real-time control of the HCl or HF concentrations in the raw gas before bag house filter:

less emissionsless lime consumtion by20 - 30 % optimisation of maintenance and replacement cycles

application combustion control in mwi24
Application: Combustion Control in MWI

Better control of the combustion process by fast closed loop measurements of O2:

less access air byapprox. 10 % less energy losseslower volume flow related costs in gas cleaningless HT corrosionmore stable steam production

without LDS 3000

withLDS 3000

steam production

primary air

secondary air

O2

CO

(Data by courtesy of RZR Herten, D, 1998)

application combustion control in mwi25
Application: Combustion Control in MWI
  • Process Quality by steam production

with LDS 3000

withoutLDS 3000

(Data by courtesy of BBP Environment GmbH, 1998)

application optimisation of sncr de nox plants

with LDS 3000

with LDS 3000

Application: Optimisation of SNCR de-NOx plants

Optimisation of SNCR de-NOx plants by fast in-situ measurements of the NH3 slip:better de-NOx efficiency less ammonia consumption by 25 – 30 %

 less ammonia slip by 50 – 70 %

less ammonia slat formation on cold surfaces

(Data by courtesy of MVR, D, 2001)

application optimisation of bag house filters27
Application: Optimisation of Bag House Filters

Optimisation of gas cleaning by lime injection by fast real-time control of the HCl or HF concentrations in the raw gas before bag house filter:

less emissionsless lime consumtion by20 - 30 % optimisation of maintenance and replacement cycles