Cement Industry CEMS

Industry
Cement
Date
2020
Location
Western Australia
Capabilities Deployed
USEPA Method 2, 3A, 4, 6C, 7E, 10, USEPA Method 16A, Performance Specifications (PS), WA CEMS Code

WA CEMS code compliant install, QA, and ongoing support.

The Challenge

Western Australia has a regulation, the WA CEMS Code, supporting the deployment, design, commissioning and ongoing quality assurance of Continuous Emission Monitoring Systems (CEMS) . It is currently the only state in Australia that does. The regulation is based on some international standards (USA and Canada) that have initial Performance Specifications for CEMS and ongoing QA Procedures. Understanding these standards and the detailed requirements is key to a successful design and commissioning of a CEMS in WA.

This particular CEMS project was quite comprehensive as it had a number of parameters to be tested. There were 2 discharge points from 2 industrial kilns requiring velocity, flow rate, temperature, particulate matter (PM), nitrogen oxides (NOx), sulphur dioxide (SO2), carbon monoxide (CO), oxygen (O2) and total reduced sulphur compounds (TRS) to be measured on a continuous basis. Some of these parameters were particularly challenging. SO2 is the most water soluble analyte on the list and was present at very low levels so it presented a challenge and TRS is an uncommon analyte at very low levels also.

The Strategy & Solution

Ektimo partnered with Horiba, Japan for the bulk of the parameters required. The main combustion components of SO2, NOx, CO and O2 were handled with Horiba's workhorse ENDA series analyser. Ektimo custom designed the TRS analyser utilising Horiba's GI-700 analyser series. The dust was handled using a light scattering instrument from SICK, Germany, the Dusthunter SB30. Velocity, flow and temp were custom designed and integrated by Ektimo using a number of manufacturers.

Given that Ektimo is NATA accredited for various emissions sampling and analysis techniques, we are in a unique position to supply, integrate and commission CEMS technologies. Ektimo were responsible for not only supply of aequyipment but supply of an outcome. The outcome required by this client (like many others) was regulatory compliance and this was what was delivered by Ektimo.

The project was challenging because of timing in relation to COVID-19 and the fact that some of our senior commissioning team (whom are based in VIC) were not able to travel to WA to support when required. Ektimo utilised the plan, do, study, act (PDSA) methodology and there were some significant adjustments to project execution over the course of the project.

This was a large and exciting project for Ektimo and we will continue to support the client throughout the long life of the CEMS.

  • View image
  • View image
  • View image
  • View image
  • View image
  • View image