CEMS and Process Analyzers

HIWACO, as a leading company in the field of CEMS analyzers, provides comprehensive services for monitoring and control of industrial pollutants. We help industries to improve their environmental performance by providing advanced analyzers for measuring flue gas parameters (such as CO, NOx, SO2 and O2), stack flowmeters and dust analyzers, in accordance with TUV and MCERTs standards and the requirements of the Iranian Environment Agency. Along with providing these gas analyzers from reputable brands such as SICK, SIEMENS, and PCME, HIWACO also provides installation, commissioning, and calibration services. Advanced technologies such as the non-radiative infrared (NDIR) method in these analyzers enable accurate and continuous measurement of pollutants, which is necessary to meet environmental standards and protect the environment.

Like many other instrumentation equipment, environmental analyzers also use different methods based on physical laws to measure the concentration of gases. In the main part of these systems, the non-dispersive infrared (NDIR) method is used. Simply, in this method, part of the infrared radiation emitted from the source, when passing through the cell containing the sample gas, is absorbed by the gas and after passing through the special filter for each gas, it is measured on the other side. Based on the amount of absorption spectrum, the desired gas concentration can be measured.

Continuous Emission Monitoring Systems (CEMS)

According to Iranian National Standard No. 22315, continuous monitoring of polluting sources and factors of industrial units is mandatory and all industrial, production, service, construction and infrastructure units that are subject to the requirement of installing and operating real-time and online pollution monitoring systems should be Install and set up the mentioned systems. These systems, which use advanced environmental analyzers, play an important role in pollution control.

Online monitoring systems are divided into two categories: online monitoring systems for chimney exhaust gases and wastewater monitoring systems. In standard 22315, the details of the installation requirements of these systems and the parameters required for measurement in various industries are stated.

Online monitoring systems for chimney exhaust gases, also known as CEMS or Continuous Emissions Monitoring Systems, generally include three main parts, which are all types of environmental analyzers:

1. Gas Analyzer
2. Dust Analyzer
3. Stack Flow Meter

* Stack exhaust gases are measured by extractive and in-situ methods. The choice between these two systems should be made based on the specific conditions of each industry and the recommendations in the available standards (including standard 22315). With the help of these environmental analyzers, it is possible to measure the concentration of different gases, including CO, NOx, SO2, O2, etc., in the chimney output sample in terms of ppm units or volume percentage (%vol).

Extractive CEMS

In-situ CEMS

Dust Analyzers:

Concentration of the gaseous components in stack exhaust is measured by gas analyzers, but there are always solid particles available in the sample, whose emission limit should be monitored online.  These solid particles that have small dimensions and have the ability to be suspended in the air flow and move along with it are known as dust. Sometimes the concentration of these particles are so high that even with unarmed eye we can witness the unpleasant sight of the release of pollutants in the environment. The density of chimney exit particles is reported in mg/m^3, which represents the mass of particles in one cubic meter unit. Considering that the increase and decrease of temperature and pressure will lead to changes in density and even the amount of absorption and transport of these particles in the air, standard conditions should be considered in order to monitor the situation. As a result, the reported values ​​are always presented in mg/Nm^3 units, which represent the state of the sample under standard conditions of 25°C temperature and 1kPa pressure.

The measurement of dust is done by three methods: electrostatic, laser and optical:

1. Electrostatic Dust Analyzer:

2. Laser Dust Analyzer:

 

3. Opacity Dust Analyzer:

Stack Flow Meter:

Gas and dust analyzers give information about the concentration of different stack parameters. Now let’s assume that in a stack carbon monoxide gas with a concentration of 50ppm is emitted. Is this information enough to determine the amount of carbon monoxide emissions in the environment? How much carbon monoxide is released from this stack each day? The answer to the first question is no! And to answer the second question, we will face the concept of fluid flow rate. If the polluting gas exits the chimney at a rate of 100 cubic meters per hour, the amount of pollution is much lower than if the exit flow of the chimney is 10,000 cubic meters per hour. This concept can be easily obtained from the relation M = ρ * V, and so far we have only calculated the density of the various parameters in the sample. As a result, the necessity of measuring the speed and flow rate of the fluid coming out of the chimney is obtained.

To measure the exhaust flow rate of the chimney, averaging pitot tube, pitot tube, venturi and ultrasonic methods can be implemented. However averaging pitot tube is the only method approved by TUV/MCERTS standards to date.  By using a larger number of holes on the probe, a kind of intermediation of dynamic pressure is done. According to Bernoulli’s law, the difference between static and dynamic pressure can be converted into the speed of the flue outlet fluid. Since the invention of this method in 1985, the pitot tube averaging method has been the main reference for measuring chimney outlet flow and many other applications.

 

The Continuous  Emission Monitoring Systems introduced in this article are suitable for installation in various industries. Some of our partner industries include:

  1. Petrochemical industries
  2. Refineries
  3. Steel industries
  4. Cement industries
  5. Power plants
  6. Non-metallic mineral industries
  7. Metal and non-metallic mines
  8. Food industries
  9. Chemical industries

At Hiwaco, we design, engineer and supply a wide range of online monitoring packages that include a variety of environmental analyzers. The components of these packages include advanced measurement analyzers, sampling systems, data collection systems, and pollutant measurement and reporting software.

Relying on the technical experience of its experts in the field of environmental and gas analyzers, Hiwaco has done many projects according to the needs of different industries in the country and provides consulting, supply, installation and commissioning services of these systems.  The foreign representatives of this company, as a powerful arm in the field of foreign trade, offer new services in the field of providing equipment and providing training services to respected employers. Hiwaco considers the operators and users of precision instruments as a member of the big family of industrial control and automation of our vast homeland of Iran and believes that the development of knowledge and technology in this field is one of the inalienable rights of experts in this region. Therefore, We have devoted our efforts to creating a dynamic network among these specialists. Among the services provided by Hiwaco in this field, the following can be mentioned:

  1. Free access to various brands and up-to-date technology in the world, including SIEMENS, SICK, ENVEA PCME, SINTROL, FUJI 

  2. Providing engineering drawings and equipment technical documents

  3. Providing documented instructions for equipment maintenance and repair in order to reduce costs

  4. On-site and high-tech workshop trainings

By completing the technical questionnaire of stack process conditions, take the last step to provide the best solutions available in your industrial unit. Our experts will contact you as soon as possible after reviewing the project.

CEMS systems usually measure gases such as CO, NOx, SO2, O2, as well as the amount of suspended particles (dust). In addition, the exhaust gas flow from the chimney is also measured by these systems.

The use of these systems is mandatory based on the national standard of Iran (No. 22315). These systems enable continuous monitoring of pollutants, which is essential for environmental protection, regulatory compliance, and improved environmental performance of industries.

In the extractive method, the gas sample is extracted from the chimney and transferred to the analyzer. In the in situ method, the analysis is directly in contact with stack gases. Choosing the right method depends on the specific conditions of each industry and the recommendations of the standards.

Measuring the exhaust gas flow rate is necessary to calculate the total amount of released pollutants. Only by having information on the concentration of pollutants and the gas flow rate, the actual amount of pollutant emission can be determined.

Yes, the analyzers offered by Hiwaco have internationally recognized certifications such as MCERTS and TUV. These certificates guarantee the high quality and accuracy of these equipment in measuring environmental pollutants.

Yes, the analyzers offered by Hiwaco have internationally recognized certifications such as MCERTS and TUV. These certificates guarantee the high quality and accuracy of these equipment in measuring environmental pollutants.

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