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INTRODUCTION

INTRODUCTION. OPSIS is a Swedish company which develops, manufactures and supplies total solutions for Ambient Air Quality Monitoring, Stack Emission Monitoring and software tools for Air Quality Management. Founded 1985

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INTRODUCTION

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  1. INTRODUCTION OPSIS is a Swedish company which develops, manufactures and supplies total solutions for Ambient Air Quality Monitoring, Stack Emission Monitoring and software tools for Air Quality Management. Founded 1985 OPSIS is represented world-wide, with internationally accepted and approved products.

  2. OPSIS PRODUCTS

  3. MAJOR APPLICATION AREAS

  4. QUALITY AND ENVIRONMENTAL MANAGEMENT • ISO 9001 • Quality • ISO 14001 • Environment • ISO 17025 • Calibration laboratory • Ackreditation laboratory

  5. OPSIS CEM SOLUTIONS

  6. CEM/PROCESS SOLUTIONS UV/IR DOAS IN-SITU SYSTEMS TUNEABLE DIODE LASER IN-SITU SYSTEMS DILUTION EXTRACTIVE SYSTEMS

  7. LASER DIODE ANALYSER • Features : • Fast response time (~ 1 sec) • Multiple paths • Multiple gases • Analyser separated from Emitter/Receiver • Long fibre lengths (< 1 km) • Low detection limits

  8. SYSTEM OVERVIEW, CEM LD500 EM060L RE060L Cabinet Laser fibre optical cable (< 1 km) Communication cable (< 2 km)

  9. Emitter Receiver with detector and A/D converter SYSTEM DESIGN Stack Digital signal LD500 analyser Ramp generator Diode laser CC Beam splitter Communicatin Interface ”Measurement” signal Reference cell Internal Detector PC Processor Beam switch ”Zero” signal / ”Reference” signal Wavelength/scanning control signal

  10. TUNING THE LASER Δλ ΔT NIR semiconductor laser Controlled variations in temperature will ”tune” the diode lasers output wavelength. The temperature variations are created by applying a sinus shaped drive current with a frequency of 1 kHz, with a temperature accuracy of 0.001 C˚

  11. ABSORPTION SPECTRUM Laser is tuned around one or a few absorbtion lines, Scanned range is typically less than 1 nm Absorbance 100% O2 HF H2O 0 % 1.35 um 1.25 um

  12. SPECTRA HANDLING ”Zero” signal ”Measurement” signal Resulting spectrum The scanned spectra are resolved into 1000 channels Measurement spectrum is divided with the Zero spectrumto obtain the resulting spectrum and to eliminate noise generated by the laser

  13. EVALUATION The cross section area of the obtained spectrum is used to calculate the concentration by use of Beer Lamberts law, compensated for line widening effects I1 I2 Ln ( I1 / I2 ) x l C = α1 – α2 + Line Widening effects due to temperature & partial pressure

  14. RESULTS Results are presented as : Concentration ( typically % (vol) , ppm or mg/m3 ) Standard deviation ( typically ppm or mg/m3) , based on the average standard deviation over the evaluated number of channels in the measured cross section spectrum Light level, expressed as dB , proportional to the amplification required on the detector.

  15. MEASURING TEMPERATURE Absorption lines Temperature can be measured by studying the proportions and relations of the absorption lines, as they change with temperature

  16. HARDWARE

  17. Central Unit • Incl. • Laser Head • Keyboard • Modem • IO 256 • RS 232 • Protocol for PLC

  18. EMITTER

  19. RECEIVER

  20. PERFORMANCE

  21. CEM/PROCESS EXAMPLE (maximum 8 paths )

  22. SIGNAL LAYOUT Emitter Receiver A/D +/-15 VDC +6 VDC 110/220-240 VAC Optical fibre cable Communication fibre cable RS232 Laser Module Multi Channel Analysing Module Computer Hard Disk +/- 15VDC Laser Module Multi Channel Analysing Module Laser Module Multi Channel Analysing Module Floppy Disk PM020 CM002 DM016 LCD IM001 OM001 110/220-240 VAC CC002 PC104 LH51n Keyboard 0-10VDC 0/4-20 mA 0/4-20mA Status I/O Modem 24 VAC +/- 12VDC +5 VDC Ioman Signal Handling System ( Optional) LD500 Analyser 110/220-240 VAC

  23. CO , CO2 , H2S • LH 514 Laser Module • Typical Applications: • Process monitoring • Tunnel monitoring • Steel plants • Cement plants

  24. O2 AND TEMPERATURE • LH 515 Laser Module • Typical Applications: • Furnace control • Steel process • Smelters • Incinerators

  25. HCL • LH 512 Laser Module • Applications: • Waste Incinerators • Chemical industry • Acid Scrubbers

  26. NH3 • LH 513 Laser Module • Applications: • DeNOx Applications • Fence-line monitoring • Fertilizer industry

  27. IPP-TAIWAN: 20 g/m3 dust , 300 degrees C, 4 metre path ER60L-Receivers Power supply for detector

  28. ER60L-Emitters

  29. CH4 • LH 516 Laser Module • Applications: • Petrochemical plants • Coke ovens • Landfill

  30. HF • LH 511 Laser Module • Applications: • Aluminium smelters • Fence line monitoring • Chemical industry

  31. POTROOM MONITORING

  32. EXAMPLE , HF DATA Pot activities

  33. CALIBRATION Calibration cell Receiver Emitter Calibration bench Standard gas Analyser

  34. CALIBRATION EQUIPMENT Rotameter(flow control) Calibrationgas Emitter Receiver Calibration bench Gas valves

  35. COMMUNICATION ALTERNATIVES +/- 15VDC CM IM001 OM001 DM016 110/220-240 VAC 0-10VDC 0/4-20 mA 0/4-20mA Status I/O Ioman Signal Handling System ( Optional) Plant DSC/PLC RS232, Alternative 4 ( Cactus, ABDH, ModBus, Siemens 3964R, Comli) Enviman ComVisioner Analyser LAN RS232, Alternative 3 RS232 RS232, Alternative 1 RS232, Alternative 2 +3

  36. STEEL PLANT APPLICATIONS

  37. EMISSION MONITORING Vizag steel plant Visakhapatnam, India,using Opsis analysers for monitoring NOx and SO2 in 15 stacks

  38. REHEATING FURNACE • Purpose • Used by all steel processing plants to heat material before treatment • Often crucial to meet right temperature • Can replace soaking pit • Operation • Oil- or gas burners heat the oven compartment • Desire to use natural- or waste gas • Comparably low dust level

  39. REHEATING FURNACE • Measurements of interest • Oxygen : decrease level to reduce fuel consumption and oxidation but keep sufficient levels for effective combustion • Carbon Monoxide: as indicator of incomplete combustion • Temperature: Important for correct process • Problems to overcome • Tendency of smoke formation at low oxygen levels • Hot environment

  40. MONITORING AFTER REHEATING FURNACE AR600 ( NO,NO2,NH3) LD500 ( O2) TAIL GAS DUCT CORUS STEEL installation in European Plant Installed early 2007 Measuring NO,NO2,NH3,O2 Temperature is approx. 450 degrees C REHEATING FURNACE SLABS

  41. CORUS STEEL MEASUREMENT DATA

  42. CORUS STEEL MEASUREMENT DATA

  43. POSCO STEEL, SLAB REHEATING FURNACE = measurement location for Oxygen d SLAB 1100°C 1200 - 1300°C 1100°C Charging zone Preheating zone Heating zone Soaking zone d : Open-path height from SLAB surface 30 – 40mm Cross section = 13 metre

  44. MODIFICATIONS MADE FOR REHEATING FURNACE APPLICATION Wall Furnace duct 1300 degrees C Laser beam Max 85 degrees C Max temperature , 40 degrees C RE060L-T RC101L+ PS Max 50 metre cable 50mm diam hole Instrument air New modifications: 1.Moved out electronic cards from RE060L, to a separate enclosure that can be installed at a distance up to 50 metre 2. Improved laser with 3 mW output compared to old laser with 0.1 mW, allows better light levels and handling of high dust levels 3.Opsis R&D department has installed a high temp heated measurement chamber which allows test environments up to 1300 degrees C .This has resulted in improved spectra handling and evaluations CF120, max 1000 metre LD500 Room temperature ( 15-30 degrees C)

  45. MONITORING CO AND HYDROCARBONS CO spectrum ( blue) recorded in reheating furnace, compared with factory spectrum( red/blue) Absorption is too a large extension covered by unknown absorption lines, most probably hydrocarbons , making it difficult to reach very low detection limits for CO ( which also have weak absorption due to temperature induced line widening effects) R&D is ongoing to overcome the problems and to reach better performance for CO Unknown compounds, most probably hydrocarbons. Can be presented as unknown compound X,Y,Z etc , if of any interest for the user.

  46. OTHER POSSIBLE APPLICATIONS Blast furnace off gases ( CO,CO2) LD converter off gases (CO,CO2,O2) Coke oven off gas/leaks ( CH4,CO,O2,BTX) Sinter plant off gas/waste gas ( H2O,HF,HCL)

  47. Technical comparison Principle Paths Comments (+/-) Signal handling

  48. CONCLUSIONS • Opsis LD500 TDL system features: • Fast response time (~ 1-10 seconds) • Semiconductor laser = reliable, long life time • Multiplexing of up to 8 paths ( = cost effective solutions) • Multiple gases ( HF,CO, CO2, H2O ,HCL,NH3, CH4…..) • Up to 4 different gas compounds in the same analyser • Long fibre cable lengths (< 1 km) • Low detection limits • Can operate in high dust environment • Can operate in high temperature environment • A minimum of maintenance

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