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Product information
product name: Multi-component smoke emission monitoring system
product brand: Skyeaglee
Product number: SK-6500
Measurement object: Flue gas emission parameters such as SO2 concentration, NOX concentration, dust particle concentration, flue gas flow, flue gas temperature, flue gas pressure and oxygen content
product description
1. System composition
The multi-component continuous emission monitoring system for smoke is composed of: a monitoring subsystem for the concentration of smoke and dust, a monitoring subsystem for gaseous pollutants (SO2 / NOX), and a monitoring subsystem for monitoring the parameters of flue gas emissions (temperature, flow, oxygen content, and pressure of the flue gas) And system control and data acquisition subsystem (DAS). The real-time data of the above monitoring items in the flue gas are measured by sampling, and can be collected, processed, stored and output centrally. The system can automatically and continuously monitor: SO2 concentration, NOX concentration, dust particle concentration, flue gas flow, flue gas temperature, flue gas pressure and oxygen content, and other flue gas parameters. The operating data collection rate of this system will not be less than 95%. Monitoring data The pass rate is greater than 90%.
1.1 Schematic diagram of the system structure and electrical / pipe cable connection diagram


2 system material (anti-corrosion characteristics)
The parts of the system that are in contact with pollutants are made of 316L stainless steel, polytetrafluoroethylene, pressure-resistant and anti-corrosion pipelines, and valves.
316L stainless steel has corrosion resistance, high temperature creep strength, and high temperature corrosion resistance. It is suitable for steel for working devices in harsh conditions such as industrial boilers and marine equipment.
Polytetrafluoroethylene is one of the materials with the best corrosion resistance in the world today. It can be used in any kind of chemical medium for a long time. It has excellent chemical stability, corrosion resistance, tightness, high lubricity and non-stickiness, and electrical insulation. And good resistance to aging. It can work for a long time at a temperature of ﹣180 ° C to ﹢ 250 ° C. Allows for rapid cooling and heating, or alternate heating and cooling. Can withstand the pressure of up to 6.4Mpa.
The use of these materials can ensure the normal and safe operation of the equipment. The sampling probe and other parts in contact with the flue gas can meet the requirements of continuous, reliable and stable operation under the operating conditions of the sintering plant. The following table shows the material of the equipment in contact with the acidic flue gas.


Serial number

Device name

Texture

1

Sampling probe

不锈钢及聚四氟乙烯 316L stainless steel and PTFE

2

Heat tracing sampling tube

PTFE tube

3

Condenser heat exchanger

Anticorrosive glass tube

4

Suction pump

Teflon

5

Peristaltic pump

Pressure and corrosion resistance

6

Analysis chamber

不锈钢 316L stainless steel

7

Connector

Teflon

3 system features
Using ultraviolet light reference absorption method to measure sulfur dioxide improves the sensitivity of the instrument and the temperature drift of the instrument is small.
Ultraviolet light reference absorption method is used to measure NOX.
 It has extensively absorbed the characteristics of similar products at home and abroad, with simple sampling and analysis methods, and stable system operation.
 The cabinet design has a reasonable layout, simple installation and debugging, and easy operation and maintenance.
 With regular backflushing and self-cleaning functions, it effectively eliminates the pollution of optical lens and clogging of the probe by smoke and dust, reduces the labor intensity of the staff, and improves the accuracy of sampling.
 Fully automatic zero calibration and correction function make the performance of the instrument more stable.
 Equipped with microcomputer communication interfaces (RS485, RS232), and has networking functions with manufacturers DCS and local environmental protection government departments.
 The SO2, NOx, and O2 analysis instruments provided by this system are arranged in the cabinet. After the pre-treatment of the sampling probe and the sample gas pretreatment system, the impact of severe working conditions on the equipment is greatly reduced, and the installation position of the analyzer is The instrument room is convenient for the protection, maintenance and repair of the equipment itself.
 The S-type pitot tube flowmeter is equipped with a differential pressure transmitter with high measurement accuracy and sensitive response, which can reflect the real working conditions in the field in real time, and provide real-time data for enterprise process control and final sewage monitoring.
 In order to prevent measurement errors of the data, both the sampling probe and the heating pipe need to be heated. The heating temperature of the sampling probe is 180 degrees (the heating temperature can be customized to 260 degrees), and the equipment also controls the probe rod of the sampling probe. , The control temperature is 180 degrees; the heating temperature of the sample mixing tube is 120 degrees, the design of the whole machine effectively prevents the adsorption of condensed water on the measured pollutants, making the measurement data more accurate.


4 operating environment
Temperature: -25 ℃ ~ 45 ℃
Humidity: ≤90%
 Atmospheric pressure: 86 ~ 106Kpa
 Flue gas temperature: <300 ℃
 Avoid the influence of strong electromagnetic fields
 Avoid contact with highly corrosive materials

2. Instrument monitoring principle
2.1 Principle of smoke and dust monitoring
SK6500 uses the principle of laser backscatter test to complete the determination of smoke (powder) dust concentration in the flue to be measured. The SK6500 embedded high-stability laser signal source passes through the flue and irradiates the smoke (powder) dust particles. The irradiated smoke (powder) dust particles will reflect the laser signal, and the intensity of the reflected signal changes in proportion to the smoke (powder) dust concentration. SK6500 detects the weak laser signal reflected by smoke (powder) dust, and can calculate the smoke (powder) dust concentration through a specific algorithm.
2.2 Flue gas monitoring principle
SO2 and NO are measured by heat pipe extraction type non-dispersive UV absorption method.
The flue gas is drawn by the sampling probe, and the particles above 5μ are filtered by the ceramic filter. In order to prevent the water in the sample gas from condensing, dissolving SO2 and NOX to affect the accuracy of the measurement, the sample gas is heated, and the heat pipe is held by the heat insulation Enter the main cabinet.
After the sample gas enters the main cabinet, the gas-liquid separator is used to separate the liquid gas-melting colloid and moisture from the sample gas, and the temperature of the sample gas is appropriately reduced. Then the gas enters the condenser, and the temperature is further reduced to 5 ° C, so that the sample gas and water are completely separated, and the influence of water is completely eliminated. After a stage of fine filtration, the effect of fine dust is completely removed, and a relatively pure sample gas is obtained, which enters the analyzer.
The SO2 molecule has a strong absorption characteristic in the ultraviolet region to measure SO2. First calibrate the instrument with a certain concentration of SO2 standard gas, and then pass in the sample gas for analysis. The calibration and analysis data are processed by a data processor to obtain the SO2 concentration.
Because SO2 has a characteristic absorption characteristic in the ultraviolet region of 280nm-320nm, while H2O and CO2 have no characteristic absorption in this region, the interference of H2O and CO2 is avoided, and the obtained data are the most reliable. In particular, the measurement results obtained from boilers with large water vapor are the most accurate.
Similarly, the measurement of NO is based on the strong absorption of NO molecules in the ultraviolet spectrum. First calibrate the instrument with a certain concentration of NOX standard gas, and then pass in the sample gas for analysis. The calibration and analysis data enter the data processor for processing to obtain the NO concentration in the sample gas.
At this time, two different light sources are used in an analysis system, and no light is split, so the system is more stable.
At the same time, the chemical sensor is used to measure the oxygen content, the high temperature sensor is used to detect the smoke temperature, the pressure sensor is used to measure the flue pressure, and the above parameters are used to convert into standard conditions. The S-type pitot tube is used to measure the flow rate of the flue gas, and the differential pressure signal is converted into an electric signal to enter the host, so as to convert the total emission.
2.3 Anti-blocking and purge system
The flue gas is collected by the sampling probe, and transmitted through the heat tracing tube, and the sample gas is pretreated for the sample gas, and finally the data is analyzed by the sample gas analyzer. Because the device has a dust filter in the sampling probe and the sample gas pretreatment part, after a long period of sample gas collection, the device needs to be blown back to achieve the purpose of preventing the device probe from blocking. The equipment's backflushing consists of two parts: the inner wall of the sampling probe and the outer wall of the sampling probe. And the purge time and sampling time of this system can be customized according to the site conditions.
2.4 Equipment protection level
The protection level table of this system is as follows:

Serial number

Device name

Protection class

1

Sampling probe

IP65

2

Flow probe

3

Flow Circuit Box

4

Soot

5

Power supply control box

6

Instrument control cabinet [installed in the analysis instrument room]

IP54

7

2 、NO、0 2 )【装置于分析仪表间】 Analytical instruments (SO 2 , NO, 0 2 ) [installed in the analytical instrument room]


3.Instrument technical indicators
3.1 Dust detector
Analysis method: Backscatter method
Measuring range (high / low) (mg / Nm3): 0 ~ 500 mg / Nm3, 0 ~ 2000 mg / Nm3 (can be customized according to buyer's requirements, and the range is automatically adjusted)
Zero drift: ≤ ± 2% FS
Range drift: ≤ ± 5% FS
The correlation coefficient: ≥0.85
Response time: ≤10S
Linearity (%): ≤ ± 1%
Ambient temperature limit (min / max) (° C): -25- +45
Electricity consumption (KVA): 2
Air requirements: dry, pollution-free, oil-free
Alarm output: switch
Output signal type: analog 4-20 mA, 485 signal
3.2 SO2 Analyzer
Measurement range (high / low): 0-500 mg / Nm3, 0-5000 mg / Nm3 (0-500-1000-2500-5000mg / Nm3 range is optional, and the range can be automatically switched)
Zero drift: ≤ ± 0.5% FS / 24h; ≤ ± 2% FS / 7d
Full-scale drift: ≤ ± 2.5% FS / 24h; ≤ ± 4% FS / 7d
Response time: <180S
Linearity (%): ≤ ± 1.5%
Sampling method: full extraction method
Analytical method: Non-dispersive UV absorption method
Ambient temperature (min / max) (° C): 15-25
Power consumption (KVA): 0.1
Instrument air requirements: dry, no pollution, no oil
Alarm output: switch
Type output signal: 4-20mA
3.3 NOX Analyzer
Measuring range (high / low): 0-500 mg / Nm3, 0-5000 mg / Nm3 (selectable range, and the range can be automatically switched)
Zero drift: ≤ ± 0.5% FS / 24h; ≤ ± 2% FS / 7d
Full-scale drift: ≤ ± 2.5% FS / 24h; ≤ ± 4% FS / 7d
Response time: <90S
Linearity (%): ≤ ± 1.5%
Sampling method: full extraction method
Analytical method: Non-dispersive UV absorption method
Ambient temperature limit (min / max) (° C): 15-25
Power consumption (KVA): 0.1
Instrument air requirements: dry, no pollution, no oil
Alarm output: switch
Type output signal: 4-20mA
3.4 Flue gas flow, pressure and flue gas temperature monitors
Measuring range: 0-800000m3 / h (flow) 0-300 ° C (temperature)
-10- + 10kPa (pressure) 0-40m / s (velocity)
Indication error: ≤ ± 1 ℃
Response time: ≤5S
Monitoring methods: Pitot tube method to measure flow, PT100 to measure temperature, pressure sensor method, differential pressure method.
Electricity consumption (KVA): 0.1
Type output signal: 4-20mA
3.5 O2 Analyzer
Analytical method: electrochemical method
Measuring range (high / low) (%): 0-25%
Precision (%): ± 1%
Response time: ≤20S
Ambient temperature limit (min / max) (° C): 15-25
Power consumption (KVA): 0.15
Resolution: 0.1%
Instrument air requirements: None
Type output signal: 4-20mA
﹣15% ≤relative accuracy≤15%
3.6 Data output screen display
Ambient temperature limit: (min / max) (° C): + 15- +25
Electricity consumption (KVA): 0.1
4. System functional structure
The flue gas consists of functions such as sampling transmission, sample gas pretreatment, cleaning purge and calibration.

4.1 Sampling transmission unit
It is mainly composed of sampling probe and heat tracing pipeline. The sampling probe can be used with a variety of different materials, structures, and lengths of sampling probes and pre-filters to meet the needs of different pollution sources.
The probe has a heater and temperature control function, which can heat up to 150 ° C (high temperature type can reach 320 ° C). Heating ensures that the temperature of the sample gas will not fall below zero.
Corrosion-resistant heat-sampling composite pipe is composed of a group of corrosion-resistant high-performance resin pipes supplemented with self-limiting heat tracing cable and compensation cable. to make.
4.2 Sample gas pretreatment
The main components of the pretreatment system include gas coolers, filters, diaphragm sampling pumps, peristaltic pumps, needle valve flow meters, etc. After the sample gas enters the pretreatment, the colloid, moisture, etc. are separated from the sample gas by a first-stage condenser, and the temperature of the sample gas is lowered below room temperature, and then filtered through the first stage. Enter the sampling pump and adjust the air flow through the regulating valve. The positive pressure sample gas is then subjected to secondary condensation and secondary filtration to make the sample gas and water well separated to obtain a relatively clean sample gas.
The function of the pre-processing system can be automatically controlled by an external analysis instrument or other equipment (such as PLC, etc.), which is in line with the latest international analysis system function trend.
4.3 Anti-purge air protection
When the CEMS system components such as the sampling head are in contact with the flue gas after installation, we will provide an anti-purge air system to prevent the flue gas from contaminating the analytical instrument components. When the anti-purge air device fails, the isolation valve will be automatically activated to protect the monitoring components.
For the heating sampling system, the CEMS system provided by us will have an automatic cleaning function, which will automatically and regularly remove the dust in the sampling probe and sampling pipeline.
4.4 Data Acquisition and Processing System (DAS)
4.4.1 Data Acquisition
DAS will interface with emissions data collection equipment, including:
 Analytical instruments and sampling systems in this specification.
Expand independent isolated constant current source signal (4-20mA) output, the constant current source signal outputs sulfur dioxide concentration (Mg / Nm3), nitrogen oxide concentration (Mg / Nm3), soot concentration (Mg / Nm3) The signal is connected to the EPA's automatic monitoring system, and the monitoring results are transmitted to the EPA's automatic monitoring system.
4.4.2 Report
DAS can automatically complete data processing and reporting and remote transmission through the serial port of the industrial control computer (connected to the company's local area network through a computer and transmit all data to the plant management system (MIS system).
4.4.3 Maintenance Services
DAS will minimize maintenance, outages and repairs. The following requirements will be fulfilled for this:
With self-diagnostic function, it can confirm whether the running status is normal.
 We will verify the remote diagnosis and troubleshooting capabilities of DAS before the factory inspection
4.4.4 Display
Provide complete emissions measurement and health records. As shown below:


  PC software diagram

                                                                IPC main interface

                                                                  IPC management main interface

Complete emissions measurement and operation records. Form a complete operating system, the data processing software is written in Chinese, and the windows Chinese interface, which can be displayed and printed with hourly, daily, monthly, annual reports and graph curves.

The screen display has the function of Chinese characters system, and can display graphics, tables, curves, bar graphs or bar graphs.
The system can display and print out the average emission concentration (mg / Nm3) and emission amount (kg / h, t / d, t / a) of dry smoke, dust, SO2 and NOx under standard conditions in any period, and can display all Relevant parameters. Record the hourly average results of dry flue gas under standard conditions (273K, 101.3KPa) every day.
It also explains the summary of corrective measures taken to ensure the continuous operation of the DAS. In addition to the above forms, the measures taken to ensure continuous system operation include status parameter display and automatic alarm functions.
Data remote networking function
Field data guarantees networking with the Municipal Environmental Protection Bureau Information Center
other
The instrument has power failure protection, automatic call recovery function and fault alarm and limit alarm device. The limit alarm device can display and save the limit concentration and the time period of the concentration. The alarm concentration limit can be set and changed manually.
The instrument needs to reserve monitoring ports for other pollutants (such as CO, CO2, etc.) or equipment reserved positions, and the software system has a corresponding room for upgrading (free upgrade).


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