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Stack Testing Applications

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    Stack testing for the energy industry

    By Teledyne API based in San Diego, CALIFORNIA (USA).

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    Fluoride emissions monitoring in aluminum smelters

    Production of aluminum from its ores at aluminum smelters results in carbon dioxide CO2, carbon monoxide CO, sulfur dioxide SO2, and hydrogen fluoride HF gas emissions during the electrolytic process phase to the atmosphere. The gas emissions need to be monitored. Typically the smelters have emission limit values (ELVs) for sulfur dioxide and hydrogen fluoride emissions. These emissions should be measured accurately and with good precision, to ensure the smelter does not exceed its emission limit values. In addition several fluoride compounds may be produced in the electrolytic bath in the event of an oxygen shortage. These compounds include carbon tetrafluoride CF4, hexafluoroethane C2F6, sulfur hexafluoride SF6, and silicon tetrafluoride SiF4. These additional emission components are problematic, as they have high Global Warming Potential (GWP) values. The GWP is a relative measure designed to demonstrate how much heat a greenhouse gas (GHG) traps in the atmosphere. Emission of one kilogram of carbon tetrafluoride into the atmosphere today has the potential of heating the atmosphere as much as 7,000 kilograms of carbon dioxide over the next 100 years.

    By Gasmet Technologies Oy based in Helsinki, FINLAND.

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    Stack emissions monitoring

    Monitoring stack emissions is a fundamental requirement for most industrial processes. Our gas analysers, dust monitors and flow monitors are designed for a wide range of applications and can operate as a fully integrated system or as stand alone instruments.

    By Codel International Ltd based in Bakewell, UNITED KINGDOM.

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    Gas monitoring instruments and systems for stack testing according to EPA test method 320

    The United States Environmental Protection Agency (EPA) has two stack testing methods for FTIR gas analyzers. Method 320 is an FTIR method for measuring wide range of organic and inorganic pollutants. Method 321 is a specific version for measuring hydrogen chloride HCl at cement kilns producing Portland cement. These methods define a quality assurance and control processes for verifying the accuracy of the results. The requirements for analytical equipment and software are defined on 40 CFR Part 60 Appendix B Performance Specification 15. Gasmet™ Gas Analyzers and Calcmet™ software have been designed to take the requirements of the performance specification into account.

    By Gasmet Technologies Oy based in Helsinki, FINLAND.

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    Gas monitoring instruments and systems for stack testing

    Several EU directives and national laws in European countries set requirements for continuous monitoring of flue gas emissions at power plants. Further requirements are set on the quality assurance of the installed measurement systems at the plants. The relevant standard in this regard is EN 14181:2004, the quality assurance of automated measuring systems. The standard dictates how to determine that the measurement systems installed for continuous emissions monitoring at a plant operate according to the directives and regulations set. Two major parts of this on-going quality assurance cycle are the QAL2 and AST procedures. A test laboratory performs tests on the systems on-site, and determines whether the systems fulfill the set requirements or not.

    By Gasmet Technologies Oy based in Helsinki, FINLAND.

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    Industrial stack emission TOC monitoring

    By Pollution Srl based in Budrio (Bologna), ITALY.

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    Determination of TOC in stack

    PROBLEM: The industrial chimney's emissions of Volatile Organic Compounds (VOCs) are becoming issues of global importance and to have an accurate knowledge about how to test VOC turns into a strategic issue. VOC emissions are quantified and monitored according to standard EN 12619, using FID analyser which uses hydrogen and other reference gases in pressurized cylinder. Operators must then approach the sampling point, often placed several meters from the ground, climbing chimneys of industrial settlements with instruments and cylinders. Is it possible making this job easier and safer? SOLUTION: Using the Polaris FID analyser produced by Pollution Srl, Italy, it is possible to carry out the VOCs monitoring according to EN 12619 without lifting accessories and heavy weights typically involved with FID analyser. Polaris FID analyser complies with this standard regulation but what is really a breakthrough and cutting-edge, is the unmatched portability and the next generation technology

    By Pollution Srl based in Budrio (Bologna), ITALY.

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    Monitoring solutions for the De-NOx plants

    In recent years the number of Selective Catalytic Reduction (SCR) and Selective Non-Catalytic Reduction (SNCR) plants for De-NOx have increased significantly. Continuous analysis of NOx prior to the de-NOx plant is often required to measure the concentration generated by the combustion process. This may be required to provide feed-forward to the Ammonia/Urea injection system and also to allow the effectiveness of the reduction process to be assessed. Continuous analysis of NOx post-reduction is required to allow the effectiveness of the reduction process to be assessed. It may also be beneficial to monitor NH3 slippage at this stage by calculating from the pre and post NOx levels if excess Ammonia/Urea is being applied.

    By Codel International Ltd based in Bakewell, UNITED KINGDOM.

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    Monitoring solutions for the gas analysers areas

    Most large coal fired power plants and combustion processes are required to monitor CO, NO and NO2 (NOx), SO2 and possibly CO2; in addition the analyser has to be normalised to Standard conditions. For this application CODEL offers the five channel GCEM 40 series which uses Infrared absorption to measure these gases plus moisture, pressure and temperature.  The analyser can be configured for single channel operation to monitor any of these gases plus CH4 and HCl.

    By Codel International Ltd based in Bakewell, UNITED KINGDOM.

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    Air sampling & monitoring systems for energy/utilities industry

    Finding efficient ways to generate, deliver and consume energy resources while reducing pollution is an ongoing quest for the Energy & Utility Industries. HI-Q has developed instrumentation geared toward monitoring emissions and the dispersal of pollutants from power plants and industrial facilities. HI-Q base-line & stack sampling equipment has been used in studies to identify and track the spread of pollutants around the globe.

    By HI-Q Environmental Products Company based in San Diego, CALIFORNIA (USA).

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    Continuous Metals Stack Monitor (CEMs)

    Cooper Environmental's Xact® 640 has the unique ability to generate high time resolution metals measurement in stacks. This unique capability has the potential to qualify as a substitution for the combination of a Hg/ PM CEMs application as well as the potential for a pollution control system feedback loop that could result in the reduction of pollution control consumables. Our systems have been site certified for compliance measurements at hazardous waste incinerator and secondary lead smelter sites.

    By Cooper Environmental Services based in Beaverton, OREGON (USA).

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    Marine monitoring solutions for the SO2/CO2/NOx monitoring

    Process control of a SO2 scrubber on a ship is a challenge due to wet and corrosive gases. In such environment, extractive gas sampling systems require high levels of maintenance in order to operate correctly. OPSIS monitoring system solves this by using an optical, non-contact, cross-duct technique. A light beam is sent across the duct or stack to be measured, and the captured light is sent through an optical fibre cable to an analyser. The analyser measures SO2, CO2 and NOx concentrations using UV and IR absorption, approved reference methods.

    By Opsis AB based in Furulund, SWEDEN.

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    Emissions Monitoring for Steel Mills

    Steel mills include a multitude of activities that generate gaseous emissions. Besides continuous emissions stack monitoring, the applications in a steel mill also include process mesaurements that provides important data to the operators in order to optimize the steel making process.

    By Opsis AB based in Furulund, SWEDEN.

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    Emissions Monitoring for Mineral Wool Production

    Opsis cross-stack monitoring systems are successfully used for emissions monitoring in mineral wool plants.

    By Opsis AB based in Furulund, SWEDEN.

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    Raw-gas monitoring for scrubber optimizing

    The consumption of scrubbing material in a scrubber is related to the mass flow of acid gases. Hydrogen chloride (HCl) and sulphur dioxide (SO2) are the major acid gases in an incinerator. By measuring the mass flow of SO2 and HCl in the raw gas going into the scrubber, it is possible to calculate the required quantity of scrubbing material.

    By Opsis AB based in Furulund, SWEDEN.

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    Continuous emissions monitoring for power plants

    OPSIS offers fully automated system solutions for continuous monitoring in power plants. The monitoring systems have been tested and approved by the German TÜV and the U.S. EPA among others, for the best performance and longest calibration interval.

    By Opsis AB based in Furulund, SWEDEN.

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    Monitoring solutions for the continuous emissions monitoring

    Multi-gas Stack Analyzers for Continuous Emissions Monitoring. FTIR and UVDOAS Analyzer Models available for Insitu Probe, Internal or External Cells, or Cross Stack Sample Acquisition.

    By Cerex Monitoring Solutions, LLC. based in Atlanta, GEORGIA (US) (USA).

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    Emissions Monitoring for Power Plants

    Opsis offers fully automated system solutions for continuous monitoring in power plants. The monitoring systems have been approved by the German TÜV and the U.S. EPA among others.

    By Opsis AB based in Furulund, SWEDEN.

  • Stack Testing for the Aluminum Industry

    ALUMINUM INDUSTRY: Performed a range of test measurements required by the promulgation of the Secondary Aluminum MACT standards. Testing included measurements of Hazardous Air Pollutants for establishing Area vs. Major Source Determinations, as well as dioxin/furan compounds associated with chlorine emissions from fluxing operations.

    By AirSource Technologies, Inc. based in Shawnee, KANSAS (USA).

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