Cement Plant Lime Kiln Stack - Emission and Stack Gas Flow Monitoring Application Brochure

Kurz Thermal Insertion Mass Flow Meter systems provide proven accuracy and reliability in the most diffi cult of EPA Title IV applications with the ability to survive for long periods of time without maintenanceCEMENT PLANT Emission and Stack Gas Flow Monitoring complex technology MADE SIMPLEA P P L I C A T I O N N O T E Volumetric Stack Flow Monitoring Discharge sources that are required to report volumetric fl ow of emissions as well as content are required by the Environmental Protection Agency (EPA) to use Continuous Emission Monitoring (CEM) Systems. Therefore, a fl ow monitoring system is an integral part of the CEM System. Cement Lime Kiln applications pose a number of challenges to obtaining these re-quired fl ow measurements including hot, moist and dirty air fl ows. Customer Application and Performance IssuesA large cement plant in the Northeast operated 3 Lime Kilns that require Stack CEM and Flow Monitoring. Two of the stacks contained ultrasonic fl ow monitoring systems and the third stack contained a Kurz Thermal Mass Flow Meter that was in service for more than 12 years. Although the K-Bar 24/Adam 155 System was operational, plant policies required that the fl ow monitoring system be updated to keep pace with new technology and to avoid unplanned shutdowns due to product obsolescence and parts support issues. When evaluating the available technologies, the customer considered both ultrasonic and thermal mass technologies. The Kurz SolutionThe customer decided on the Kurz K-Bar 2000B/Adam 155 Thermal Mass Flow Metering system, which provided a number of key benefi ts over the ultrasonic options.First, the particulate matter being emitted can build up on other technolo-gies, requiring an Air Purge System to provide consistent and reliable data. One true advantage in this application is the ability of the Kurz technology to maintain sensor performance and survive for long periods of time with-out maintenance, even in extreme dirty and harsh environments.Secondly, because of this harsh environment, the EPA specifi es certain sys-tem requirements that will provide for velocity/fl ow correction if a sensor becomes non-operational. The Kurz Adam 155 Flow Computer and Trans-mitter controller contains fi rmware and software addressing this specifi c EPA requirement for stack emissions. The Adam 155’s Flow Perfect™ Soft-ware is capable of recognizing problems from any of the individual velocity sensors or electronics and will “kick-out” the velocity reading in question. Once it eliminates the particular data, it applies a correction factor to the remaining sensors. This advanced technology provides the fl ow velocity correction mandated by the EPA. Benefi ts of the Kurz Solution• Easy Installation• Satisfi es EPA require-ments for fl ow velocity correction • Extremely Low Mainte-nance even Under Harsh Conditions • Rugged and Accurate Dual Sting Sensors • High Repeatability• Process Temperatures up to 500°CCement Plant Lime Kiln StackEmission & Stack Gas Flow MonitoringPAGE 2 DCN 364036 Copyright © 2009 Kurz Instruments Inc.The Kurz Solution - Continued from Previous PageThe third benefi t of the Kurz K-Bar 2000B/Adam 155 Thermal Mass Flow Metering System was the result of the installation cost. Since the Ultrasonic System required the sending and receiving devices be mounted at an angle across the stack fl ow area, a second platform would have been required to support this design requirement. Since the Kurz K-Bar 2000B solution did not require such a platform the cost savings on the installation was signifi cant. The fi nal benefi t of the Kurz system was the overall simplicity of the design, setup and programming, installation and proven reliability demonstrated by the 12 year old K-Bar 24 system.Kurz Velocity Sensor Technology The Kurz K-Bar 2000B contains Fast Dual Metal Clad™ mass fl ow sensors that use reference grade platinum RTD’s with 0.25% repeatability. This, coupled with the extremely high signal-to-noise ratio of the constant temperature electronic circuitry, produces the most repeatable fl ow signal available in the industry. Our rugged and reliable FD “Dual Sting” fl ow sensor has repeatedly proven to work with little maintenance in “very dirty and hot” Combustion Air and Stack fl ow applications. Unlike many other devices, the Kurz devices will not plug or jam and can operate in low velocity high turndown applications while providing stable, reliable and repeatable velocity/fl ow measurements. About Kurz InstrumentsKurz Instruments has maintained a reputation for designing and manufactur-ing Thermal Mass Flow Transmitters for industrial air and gas fl ow applica-tions. Our engineers, product development specialists and management staff have developed products to operate in the harshest of environments. For more than 30 years, our entire team has provided solutions to our customers most demanding and diffi cult applications. Kurz products are used in a wide variety of industrial applications including combustion air, aeration air and digester gas, nuclear power plants, pump protection, fl are stack monitoring and compressed air, to name only a few.Kurz Instruments, Inc.2411 Garden RoadMonterey, CA 93940 800-424-7356 Toll Free Phone831-646-5911 Local Phone831-646-8901 Faxsales@KurzInstruments.comwww.KurzInstruments.comPAGE 3 DCN 364036 Copyright © 2009 Kurz Instruments Inc. The bottom photo shows the particulate matter that is common in Lime Kiln stacks and demonstrates how the Kurz K-Bar Sensor Window and Sensor Element remains clean and free of buildup. Thereby, Sensor/Sys-tem performance is maintained and downtime for maintenance is virtually eliminated.