Continuous Emissions

Monitoring Systems

Engineering
&
Design

Industrial and Utility

Applications

a technical solution to
meet every need…
CEMTEK Environmental Inc.
3041 S. Orange Ave.
Santa Ana, CA 92707
800-400-0200
www.cemteks.com
© 2009 Cemtek Environmental, Inc.
 Continuous Emission Monitoring
CEMS are required for a variety of
different applications and can be found
at facilities such as:

Turbines-Gas & Oil Fired, Boilers-Gas,

Oil & Coal Fired, IC Engines-Landfill
Gas, Wastewater Treatment-Sewage
Sludge Incinerators & IC Engines,
Refinery, Waste to Energy,
Cogeneration & Process Applications

© 2009 Cemtek Environmental, Inc.

 CEMS
&
Process Monitors

Ambient, Dilution, Full-Extractive Dry,

Hot-Wet Extractive
Chemiluminescence, Fluorescence, NDIR, GFC, Zirconia,
Paramagnetic, Tunable Diode Laser, Heated FID (Flame
Ionization Detection) and FTIR
Low NOx/NO/NO2/NH3/SO2/SO3/CO/CO2/O2/VOCs,
Mercury, Opacity, Flow, Ozone, Calibrators and PM

© 2009 Cemtek Environmental, Inc.

 CEMS TYPES

FULLY EXTRACTIVE (DRY BASIS)

DILUTION EXTRACTIVE (WET BASIS)
OTHERS:
•FULLY EXTRACTIVE (HOT/WET)
•IN-SITU (CROSS STACK or PROBE)
•EX-SITU (CLOSE COUPLED EXTRACTIVE)

© 2009 Cemtek Environmental, Inc.

 FULLY EXTRACTIVE - Dry Basis
 Sample Gas Dried To A Dew-point Of +2°C
 Excellent Performance In Low Concentrations
 Good Performance In High Concentrations
 Requires Preventative Maintenance
 MEASUREMENT TYPES: Chemiluminescence,
NDIR, UV Absorption, UV Fluorescence,
Paramagnetic, Zirconia, FTIR, DOAS, IR-GFC
 Heated Probe Filter And Heated Sample Line
 Moisture Volume Needs to be Determined –
Constant or Measured
© 2009 Cemtek Environmental, Inc.
 Sample Line

Probe

NOx

Pump

Cooler
Cal CO
Gas
O2
Inst. Air

Extractive Flow Schematic

© 2009 Cemtek Environmental, Inc.

 SAMPLE
CONDITIONING BAY

© 2009 Cemtek Environmental, Inc.

 SAMPLE COOLER

SAMPLE PUMP PERISTALTIC

PUMP

© 2009 Cemtek Environmental, Inc.

 Fully Extractive Heated Probe

© 2009 Cemtek Environmental, Inc.

 SYSTEM CONTROL
PANEL

SAMPLE FLOW
CONTROL PANEL

© 2009 Cemtek Environmental, Inc.

 SAMPLE PROBE WITH
HEATED FILTER

© 2009 Cemtek Environmental, Inc.

 DILUTION EXTRACTIVE - Wet Basis
 DILUTES SAMPLE WITH CLEAN DRY AIR
 MINIMIZES MAINTENANCE
 USES HIGHLY SENSITIVE GAS ANALYZERS
 LOWER COST SAMPLE LINE – FREEZE
PROTECTED
 SIMPLE TO OPERATE
 MEASUREMENT TYPES: Chemiluminescence
(NOx), UV Fluorescence (SO2), GFC-IR (CO), NDIR
(CO2 diluent)

© 2009 Cemtek Environmental, Inc.

 Dilution Extractive Flow Schematic

© 2009 Cemtek Environmental, Inc.

 Blow Back Cal Bypass Dilution
(purge) Gas Air Air

Stack
Vacuum

Pressure Diluted
Comp Sample
Out

DILUTION PROBE SCHEMATIC (Out-Of-Stack)

© 2009 Cemtek Environmental, Inc.

 Side View

Pressure Vacuum Diluted

Comp Dilution Sample
Cal Gas
Air Out
DILUTION PROBE ARRANGEMENT (Out-Of-Stack)

© 2009 Cemtek Environmental, Inc.

 Bypass
Air

Top View

Heated
Filter

DILUTION PROBE ARRANGEMENT (Out-Of-Stack)

© 2009 Cemtek Environmental, Inc.

 Heated
Block

Bypass Blow
Air Back Air

DILUTION PROBE ARRANGEMENT (Out-Of-Stack)

© 2009 Cemtek Environmental, Inc.

 DILUTION CONTROL PANEL

GAS
ANALYZERS

© 2009 Cemtek Environmental, Inc.

 TRACE GAS
SCRUBBERS

ACCUMULATOR
TANK

HEATLESS AIR
DRYER

© 2009 Cemtek Environmental, Inc.

 CEMS SELECTION AND DESIGN
Application Choices – Dilution or Extractive
 Pollutant Concentrations
 Lowest constituent dictates
 May preclude dilution due to analyzer
limitations
 Mass Emissions Requirement
 Dilution is a wet basis measurement
 Requires flow measurement

© 2009 Cemtek Environmental, Inc.

 APPLICATION CHOICES
Dilution or Fully Extractive
Advantages Disadvantages
Dilution Low maintenance Low concentrations
Extractive More reliable (Ratios above 100:1)

Coal fired
Some oil fired
Fully Low concentrations Higher maintenance
Extractive Gas fired Lower availability
Some oil fired
Fuel flow meter

© 2009 Cemtek Environmental, Inc.

 Continuous Emissions
Monitoring Systems

Engineering
&
Design

Gas Turbines

a technical solution to
meet every need…
CEMTEK Environmental Inc.
3041 S. Orange Ave.
Santa Ana, CA 92707
800-400-0200
www.cemteks.com
© 2009 Cemtek Environmental, Inc.
 Gas Turbine Process Diagram
Turbine Exhaust CEMS
SCR Inlet CEMS
NOX
CO NOX
O2
NH3*
Raw Material
Dryer THC

Regulatory Compliance CEMS Process CEMS

© 2009 Cemtek Environmental, Inc.

 Gas Turbine
Air Quality Control Systems
Natural Gas Fired Turbine
SCR NOX Control

CO Catalyst

© 2009 Cemtek Environmental, Inc.

 Conventional CEMS Ammonia Slip
Measurement Techniques
Differential NOX/NH3 Converter Method
Turbine Exhaust NOX + Converted NH3
Turbine Exhaust NOX

On Stack Converter
4 NH3 + 5 O2 = 4 NO + 6 H2O
*High temperature catalyst

NH3 slip (ppm) = NOX (ppm) (total converted) – NOX (ppm) (unconverted)
© 2009 Cemtek Environmental, Inc.
 Conventional CEMS Ammonia Slip
Measurement Techniques
Inlet/Outlet Differential NOX Method

Turbine Exhaust NOX

SCR Inlet NOX

NH3 slip = NH3 fed – (NOX in – NOX out)

© 2009 Cemtek Environmental, Inc.
 Conventional CEMS Ammonia Slip
Measurement Techniques
Direct NH3 Measurement Method

Turbine Exhaust NH3

© 2009 Cemtek Environmental, Inc.

 Continuous Emissions
Monitoring Systems

Engineering
&
Design

Coal Fired Utility Boilers

a technical solution to
meet every need…
CEMTEK Environmental Inc.
3041 S. Orange Ave.
Santa Ana, CA 92707
800-400-0200
www.cemteks.com
© 2009 Cemtek Environmental, Inc.
 Coal Fired Utility Boiler
Process Diagram
SCR/SNCR NOX NH3 Slip

Stack Exhaust CEMS

NOX
SO2
CO
FGD Inlet SOX PM
Hg
HCl
Flow

Regulatory Compliance CEMS Compliance/Process CEMS Process CEMS

© 2009 Cemtek Environmental, Inc.

 Coal Fired Utility Boiler
Air Quality Control Systems
SCR/SNCR Activated Carbon Injection
NOX Control Mercury Control

Particulate/
Opacity
WFGD/DFGD
Control
SOX Control

© 2009 Cemtek Environmental, Inc.

 Coal Fired Boiler FGD Scrubber
General CEMS Design
Wet & Dry FGD CEMS Application
 CEMS Design Considerations
 Probe Design and Accessories
 Corrosion resistant materials for probe tube construction to
prevent attack from acid gases (Hastelloy, Inconel, etc.)
 Heated probe tube in wet stack (saturated) conditions to help
prevent corrosion
 Impingement shield on probe inlet to prevent clogging from
wet particulate
 Demisters to knock down entrained water in sample prior to
entering dilution orifice
 Probe accessibility for maintenance and service
 Stack clearances for probe installation and removal
 Temperature effects on the density of the flue gas minimized
by the use of a heated orifice

© 2009 Cemtek Environmental, Inc.

 Coal Fired Boiler FGD Scrubber
General CEMS Design
Wet & Dry FGD CEMS Application
 CEMS Design Considerations
 Sample Umbilical Design
 Sample line routing and access. Keep in mind access for stack
testers and maintenance personnel.

Test
Port

 Heated umbilical for low dilution ratios (higher moisture

concentrations)
 Heated umbilical for low CO measurement applications in
conjunction with stainless steel tubing
© 2009 Cemtek Environmental, Inc.
 Coal Fired Boiler FGD Scrubber
General CEMS Design
Wet & Dry FGD CEMS Application
 CEMS Design Considerations
 Dilution Air Cleanup Design
 Plant air cleanup panel to condition air to instrument grade
may be required
 Redundant dilution air cleanup for added system availability
 CO and trace gas scrubbers for removal of measured gases

CO2 Adsorbers &

CO Scrubbers
© 2009 Cemtek Environmental, Inc.
Trace Gas Scrubbers
 Stack Flow Measurement
Stack Flow Measurement Techniques
Used for mass emissions reporting requirements (lbs/hr,
tons/year, etc)

 DIFFERENTIAL PRESSURE
 S Type Pitot
 Averaging Pitot – Annubar
 Accuracy Limited At Low Flow
 UTRASONIC
 Requires Electronic Cal Check
 THERMAL SENSING
 Requires Electronic Cal Check
 OPTICAL

© 2009 Cemtek Environmental, Inc.

 Averaging Pitot Flow – Differential Pressure

© 2009 Cemtek Environmental, Inc.

 Ultrasonic Flow - Acoustic

© 2009 Cemtek Environmental, Inc.

 Thermal Sensing

© 2009 Cemtek Environmental, Inc.

 STACK FLOW MONITORING

Optical Flow Sensor

© 2009 Cemtek Environmental, Inc.

 STACK FLOW MONITORING

RECEIVER

TRANSMITTER
A

LED BEAM PATH

FLOW

DEM PREAMP

DEM PREAMP

AMP ADC
Vel
Corr
DIGITAL COVARANCE RS-232 OUT
A
PROCESSOR PROCESSOR
B 4/20mA OUT

AMP ADC

OFS SIGNAL PROCESSOR ELECTRONICS ENCLOSURE

Optical Flow Sensor

© 2009 Cemtek Environmental, Inc.
 Conventional Opacity/Particulate
Matter Measurement Techniques

Principle of Detection
 Double pass systems for the dust loaded
measuring path with light in the visible
range.
Compliance for 10-20% Opacity
 To meet EPA Performance Standard PS-1
 Traditional Optical designs are used
 Traditional Accuracy and Drift are Acceptable
Compliance for 0-10% Opacity
 New design platforms to meet PS-11
 Traditional Drift removed
 Improved Optical Design

© 2009 Cemtek Environmental, Inc.

 Conventional Opacity/Particulate
Matter Measurement Techniques
Concave mirror

LED Reflector
Beam splitter
aktive measuring path

Measurement receiver Monitor receiver

 Green LED
 Inside Regulation Wavelength
 No Optical filters required
 Long Life
 Electronic Modulation

© 2009 Cemtek Environmental, Inc.

 Utility Boiler MACT

Possible Timeline for Environmental Regulatory Requirements for the Utility Industry
© 2009 Cemtek Environmental, Inc.
 Mercury
Monitoring
Technologies
and
Detection
Principles

a technical solution to
meet every need…
CEMTEK Environmental Inc.
3041 S. Orange Ave.
Santa Ana, CA 92707
800-400-0200
www.cemteks.com Mercury Fountain by Alexander Calder
Joan Miro Museum in Barcelona, Spain
© 2009 Cemtek Environmental, Inc. Copyright ©2008 Theodore W. Gray
 Mercury Monitoring

Regulations, where do we stand?

 Since vacating the Clean Air Mercury Rule (CAMR), the
implementation of mercury monitoring has primarily fallen on
the state and local regulators.
 The EPA often uses Consent Decrees to mandate mercury
monitoring.
 Cement MACT requires plants to monitor mercury emissions
in kiln exhaust.

 More industry monitoring on the horizon.

 Utility Boiler MACT

© 2009 Cemtek Environmental, Inc.

 Mercury

 Detection Technologies
 Continuous Monitoring
Cold Vapor Atomic Fluorescence
Example: Thermo Freedom Mercury Series
 Continuous Batch Measurement
Pre-Concentration on Gold Filter, Thermal Desorbtion, Atomic
Fluorescence
Example: Tekran Series 3300
 Long Term Batch Measurement
Sorbent Trap or Appendix K
Example: Apex Instruments

© 2009 Cemtek Environmental, Inc.

 Particulate Matter
Monitoring
Technologies
and
Detection
Principles

a technical solution to
meet every need…
CEMTEK Environmental Inc.
3041 S. Orange Ave.
Santa Ana, CA 92707
800-400-0200
www.cemteks.com
© 2009 Cemtek Environmental, Inc.
 PM CEMS

Why are PM CEMS Important?

 Opacity correlates poorly to PM emissions
 PM CEMs can address the shortfalls of continuous opacity
monitors (COMs)
 With the onset of continuously decreasing limits of SO2 and the
concern of SO3 from SCR installations, wet scrubbers have
proven to be a highly efficient means of reducing SO2, SO3 and
fine particulates; however a wet gas effluent is a result. This
result is in the form of wet particulate and water droplets.
 The proposed Utility MACT sets new standards for PM as a
surrogate for non-Mercury metals.
Where are PM CEMS Being Installed?
 Proposed Boiler MACT applications (Industrial and Utility)
 Scrubbed stack PM monitoring
 New coal-fired power plant permits
 EPA consent decrees

© 2009 Cemtek Environmental, Inc.

 PM CEMS

40CFR60 Appendix B Performance Specification 11

 The purpose of PS-11 is to establish the initial installation and
performance procedures required for the evaluating the acceptability
of a PM CEMS.
 PS-11 applies to any PM CEMS that is required by Title 40 of the
Code of Federal Regulations (CFR) to install and operate a PM CEMS.
 PS-11 requires a site to perform initial installation and calibration
procedures that confirm the acceptability of the PM CEMS.
 A site specific correlation of the PM CEMS must be developed to
establish response against manual gravimetric reference method
measurements including Method 5 and 5I and Method 17.
PS-11 provides:
 Guidelines for selecting a PM CEMS
 Installation location guidance
 Procedures for certifying a PM CEM
 Minimum performance limits
 Example calculations
© 2009 Cemtek Environmental, Inc.
 PM CEMS

Principal Technologies used

 Light Scattering
 Can measure very low dust levels.
 Some practical problems.
 Beta Attenuation
 Uses continuous paper tape filter.
 Dust particles adhering to the filter absorb beta-particles
emitted by radioactive source. This absorption gives a
measure of dust density.
 Probe Electrification (Triboelectric)
 Sensitive
 High accuracy
 Requires compensation for flow, temperature, etc.

© 2009 Cemtek Environmental, Inc.

 Tunable Diode Laser
Spectroscopy
Detection Principles
For Monitoring
NH3, HCl & HF

a technical solution to
meet every need…
CEMTEK Environmental Inc.
3041 S. Orange Ave.
Santa Ana, CA 92707
800-400-0200
www.cemteks.com
© 2009 Cemtek Environmental, Inc.
 NH3 & HCl Monitoring

Purpose for monitoring Ammonia (NH3) Slip

 Regulatory emissions limits for both NOX and NH3 slip
 Overall process efficiency
 Corrosion and maintenance of equipment (air preheater, etc.)
 Economic Considerations:
 NOX emission trading credit maximization
 Contamination of fly ash
 Cost of consumable ammonia/urea
Purpose for monitoring HCl
 Regulatory emissions limits becoming more common
requirements in air permits
 New rules call for continuous monitoring (Utility MACT,
Cement MACT)

© 2009 Cemtek Environmental, Inc.

 Tunable Diode Laser
Measurement Technique
When no gas present…

Io

When gas present…

Absorbed intensity, δI = Io - I
© 2009 Cemtek Environmental, Inc.
 Federal Regulations

CEMS Operating Specifications

 Part 60 CEMS operating specifications are found in 40 CFR 60,
Appendix B – Performance Specifications, and Appendix F –
Quality Assurance Procedures
 Part 75 CEMS operating specifications are found in 40 CFR 75,
Appendix A – Specifications and Test Procedures, and Appendix
B – Quality Assurance and Quality Control Procedures.

© 2009 Cemtek Environmental, Inc.

 CEMS Initial Certification Testing
Requirements
40 CFR Part 60
7-Day Calibration Drift
NOX, SO2 ≤ 2.5% of span
CO2, O2 ≤ 0.5% difference
CO ≤ 5.0% of span for 6 out of 7 days
Flow ≤ 3.0% of span

Response Time – PS-4A

CO ≤ 1.5 minutes
PS-4A is only used for low CO emitters (less than 200 ppm expected concentration) or dual ranged CO
analyzers. A response time test is not required for NOX, SO2, O2/CO2 analyzers under Part 60
specifications.

Calibration Error – PS-4B

CO/O2 ≤ 5% of reference value
PS-4B is only used for CO and O2 monitors required for reporting CO emission rate (lb/mmBtu). CO is
typically dual-ranged. All of the tests required from PS-4 and 4A are required along with the additional 3-
point calibration error check. Tests are performed on both the CO and O2 monitors, all ranges.

Opacity Monitor
Calibration Error ≤ 3.0% error
Response Time ≤ 10 seconds
Calibration Drift ≤ 2.0% error
Recording Check ≤ 2.0% accuracy

© 2009 Cemtek Environmental, Inc.

 CEMS Initial Certification Testing
Requirements
40 CFR Part 75
Conditions for
Test Monitor Performance Specification Alternate
using alternate
±2.5% of span value, on Span value < 200
SO2 or NOX |R – A| ≤ 5 ppm
each of the 7 days ppm
7-day calibration ±3.0% of span value, on Applies only to DP-
Flow |R – A| ≤ 0.01”H2O
error test each of the 7 days type flow monitors
|R – A| ≤ 0.5% CO2 or O2, on
CO2 or O2 NA NA
each of the 7 days
|R – Aavg| ≤ 5.0% of the
The alternate
reference gas tag value, at
Linearity check SO2 or NOX |R – Aavg| ≤ 5 ppm specification may be
each of the three calibration
(span ranges ≤ 30 used at any gas level
gas levels
ppm are exempt
|R – Aavg| ≤ 5.0% of the
from the linearity The alternate
reference gas tag value, at |R – Aavg| ≤ 0.5% CO2 or
requirement) CO2 or O2 specification may be
each of the three calibration O2
used at any gas level
gas levels
Cycle time test All gas monitoring systems 15 minutes NA NA
T, P and ∆P transmitters
are accurate to 1.0% at Alternate
Fuel flowmeter 2.0% of full scale, i.e., the each of three levels, or specification applies
Fuel flowmeters
accuracy test upper range value have a combined only to orifice, nozzle
accuracy ≤ 4.0% at any and venturi meters.
level

© 2009 Cemtek Environmental, Inc.

 CEMS Initial Certification Testing
Requirements
Clean Air Act Section 112
Conditions for
Test Monitor Performance Specification Alternate
using alternate
7-day calibration
±5.0% of span value, on Span value equal to
error test Hg CEMS |R – A| ≤ 1.0 µg/scm
each of the 7 days µg/scm
|R – Aavg| ≤ 5.0% of the span
System integrity
Hg CEMS with converters value, at each calibration gas NA NA
check
level
Linearity check
|R – Aavg| ≤ 10.0% of the
(span ranges ≤ 30 The alternate
reference gas tag value, at
ppm are exempt Hg CEMS |R – Aavg| ≤ 1.0 µg/scm specification may be
each of the three calibration
from the linearity used at any gas level
gas levels
requirement)

© 2009 Cemtek Environmental, Inc.

 Relative Accuracy Test Audit

Relative Accuracy Test Audit is…

 The absolute mean difference between the CEMS and the
reference method (RM), plus the 2.5% error confidence coefficient
of a series of tests, divided by the mean of the RM tests or the
applicable emission standard.

d + CC
RA = x 100%
RM
RA = Relative Accuracy
|d| = Absolute value of mean difference (CEMS – RM)
CC = Confidence Coefficient
RM = Average Reference Method Value

 Comparison of CEMS Data To Reference Method Data

 A Minimum Of 9 Reference Method Runs

© 2009 Cemtek Environmental, Inc.

 Relative Accuracy Test Audit

Relative Accuracy Test Audit is not…

 A Source/Compliance Test
 NOT Directly Concerned With Emission Levels
 Primarily How CEMS Data Compares To Reference Method
Data
 Not Exempt From Emission Limits During The Rata
 Nine Individual Tests
 There Is No “Pass/Fail” Criteria For Each Individual Run
 Not intended for process CEMS

© 2009 Cemtek Environmental, Inc.

 Relative Accuracy Test Audit
Requirements

 Part 60  Part 75
 RA ≤20% or 10% of the  RA ≤10% or 15 ppm for
applicable emission NOx/SO2 (other alternative
standard for NOx/SO2 criterion exists)
 RA ≤20% or 1.0% difference  RA ≤10% or 1.0% difference
CO2/O2 CO2/O2
 Test to be conducted with  Test to be conducted with
unit operating at more than unit operating at normal
50% capacity or at normal load as specified in 75 App
load A, 6.5.2.1
 Repeat every four calendar  Repeat every 2 QA
quarters operating quarters unless
RA ≤ 7.5%, then repeat
every 4 QA operating
quarters
 Flow RATA required at three
operating loads*
© 2009 Cemtek Environmental, Inc.
 CEMS Audit Requirements

40 CFR Part 60
 Daily calibration drift – all analyzers
 Quarterly Cylinder Gas Audits (CGAs) – gas analyzers
 Quarterly calibration error – opacity monitor
 Quarterly leak check – DP type stack flow monitors
 Annual RATA – all analyzers

40 CFR Part 75
 Daily drift check – all analyzers
 Daily interference check – stack flow monitors
 Quarterly linearity check – gas analyzers
 Quarterly leak check – DP type stack flow monitors
 Quarterly stack flow-to-load analysis – stack flow monitors
 Semiannual/annual RATA & bias check – all analyzers
 Annual fuel flowmeter accuracy check – Part 75 Appendix D
reporting systems

© 2009 Cemtek Environmental, Inc.

 Quarterly Audit Requirements

 Part 60 CGA  Part 75 Linearity

 2 gases:  3 gases:
Low (20-30% of span) Low (20-30% of span)
Mid (50-60% of span) Mid (50-60% of span)
 Criteria < 15% or ≤5 ppm High (80-100% of span)
difference  Criteria < 5% or ≤5 ppm
 Performed in 3 quarters difference
per year with RATA  Performed in every QA
performed in 4th quarter operating quarter

© 2009 Cemtek Environmental, Inc.

 Part 60 vs. Part 75

Differences
 Span and Range requirements
 Calibration Drift vs Calibration Error Check
 Cylinder Gas Audit vs Linearity Check
 RATA Requirements
 Reference Method Requirements
 Moisture Monitoring Requirements

Reference Method Differences

 40 CFR 60; test methods are specified in the applicable subpart
 40 CFR 75; test methods are specified in 75.22
 Not all of the sections in the reference methods are adopted in
Part 75

© 2009 Cemtek Environmental, Inc.

 Valid Data Requirements

40 CFR Part 60
 A completely separate topic!
 Individual states have different interpretations of valid data
requirements under Part 60

40 CFR Part 75
 Valid data requirements well defined under Part 75
 Data substitution routines for missing data
 Requires 100% valid data

© 2009 Cemtek Environmental, Inc.

 Questions?

Contact Information
Tim Kuiken
CEMTEK Environmental
Midwest Regional Sales Manager
Ph: (714) 904-6276
[email protected]

Keith Crabbe
CEMTEK Environmental
Engineering Manager
Ph: (714) 437-7100 Ext. 221
[email protected]

© 2009 Cemtek Environmental, Inc.