OPSIS is a Swedish company which develops, manufacturesand 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.

INTRODUCTION

OPSIS PRODUCTS

MAJOR APPLICATION AREAS

ISO 9001• Quality

ISO 14001• Environment

ISO 17025• Calibration laboratory• Ackreditation laboratory

QUALITY AND ENVIRONMENTAL MANAGEMENT

OPSIS CEM SOLUTIONS

CEM/PROCESS SOLUTIONS

UV/IR DOAS IN-SITU SYSTEMS

TUNEABLE DIODE LASER IN-SITU SYSTEMS

DILUTION EXTRACTIVE SYSTEMS

Features :Features :

• Fast response time (~ 1 sec)Fast response time (~ 1 sec)

• Multiple pathsMultiple paths

• Multiple gasesMultiple gases

• Analyser separated from Emitter/ReceiverAnalyser separated from Emitter/Receiver

• Long fibre lengths (< 1 km)Long fibre lengths (< 1 km)

• Low detection limitsLow detection limits

LASER DIODE ANALYSER

LD500

Cabinet

EM060L RE060L

Communication cable (< 2 km)

Laser fibre optical cable (< 1 km)

SYSTEM OVERVIEW, CEM

LD500

PC

LD500 analyser

CCBeam splitter

Beam switch

Stack

Emitter Receiver with detector and A/D converter

Digital signal

Communicatin Interface

Processor

”Zero” signal / ”Reference” signal

”Measurement” signal

Internal Detector

Ramp generator Diode laser

Reference cell

Wavelength/scanning control signal

SYSTEM DESIGN

ΔT Δλ

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˚

NIR semiconductor laser

TUNING THE LASER

LD500

1.25 um 1.35 um

100%

0 %

Absorbance

HFH2O

O2

Laser is tuned around one or a few absorbtion lines,Scanned range is typically less than 1 nm

ABSORPTION SPECTRUM

”Zero” signal

”Measurement” signal

Resulting spectrum

SPECTRA HANDLING

The scanned spectra are resolved into 1000 channels

Measurement spectrum is divided with the Zero spectrum to obtain the resulting spectrum and to eliminate noise generated by the laser

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

EVALUATION

Ln ( I1 / I2 ) x l α1 – α2

C =

I1

I2

+ Line Widening effects due to temperature & partial pressure

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.

RESULTS

MEASURING TEMPERATURE

Absorption lines

Temperature can be measured by studying the proportions and relations of the absorption lines, as they change with temperature

HARDWARE

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

EMITTER

RECEIVER

PERFORMANCE

Gas Typical Range

Detection limit ( 10 metre)

CO2 0-100% 0.01%

CO2 0-10000 ppm 0.5 ppm

O2 0-21% 0.01%

H2O 0-100% 0.01%

CO 0-100% 0.01%

CO 0-10000 ppm 10 ppm

CH4 0-100% 0.01%

CH4 0-10 000 ppm 0.2 ppm

NH3 0-1000 ppm 0.05 ppm

HCL 0-1000 ppm 0.05 ppm

HF 0-50 ppm 0.005 ppm

Temperature 0-1500 ° C +/- 5 ° C

CEM/PROCESS EXAMPLE(maximum 8 paths )

Multi Channel

Analysing Module

Multi Channel

Analysing Module

Laser ModuleLaser Module

Laser Module

Multi Channel

Analysing Module

Computer

Hard Disk

24 VAC

Floppy Disk

LCDLH51n CC002 PC104

+/- 12VDC+5 VDC

110/220-240 VAC

LD500 Analyser

A/D

+/- 15VDC

+/-15 VDC+6 VDC

Optical fibre cable

Communicationfibre cable

Emitter Receiver

PM020 CM002

IM001 OM001

DM016

0-10VDC0/4-20 mA

0/4-20mA StatusI/O

Ioman Signal Handling System ( Optional)

RS232

110/220-240 VAC

110/220-240 VAC

Keyboard

Modem

SIGNAL LAYOUT

LH 514 Laser ModuleLH 514 Laser Module

Typical ApplicationTypical Applicationss: : • Process Process mmonitoringonitoring•Tunnel monitoringTunnel monitoring•Steel plantsSteel plants•Cement plantsCement plants

CO , CO2 , H2S

LH 515 Laser Module LH 515 Laser Module

Typical ApplicationTypical Applicationss:: • Furnace controlFurnace control• Steel processSteel process• SmeltersSmelters• IncineratorsIncinerators

O2 AND TEMPERATURE

LH 512 Laser Module LH 512 Laser Module

ApplicationApplicationss: : • Waste IncineratorsWaste Incinerators• Chemical industryChemical industry• Acid ScrubbersAcid Scrubbers

HCL

LH 513 Laser Module LH 513 Laser Module

ApplicationApplicationss::

• DeNODeNOxx Application Applicationss

• Fence-line monitoringFence-line monitoring

• Fertilizer industryFertilizer industry

NH3

ER60L-Receivers Power supply for detector

IPP-TAIWAN: 20 g/m3 dust , 300 degrees C, 4 metre path

ER60L-Emitters

LH 516 Laser Module LH 516 Laser Module

ApplicationApplicationss:: • Petrochemical Petrochemical plantsplants• Coke ovensCoke ovens• LandfillLandfill

CH4

LH 511 Laser Module LH 511 Laser Module

ApplicationApplicationss: : • Aluminium Aluminium smelterssmelters• Fence line monitoringFence line monitoring• Chemical industryChemical industry

HF

POTROOM MONITORING

Pot activities

EXAMPLE , HF DATA

LD500

Calibration bench

Analyser

Standard gas

Calibration cell

Receiver

Emitter

CALIBRATION

LD500

Calibrationgas

Rotameter(flow control)

Receiver Emitter

Calibration bench Gas valves

CALIBRATION EQUIPMENT

Analyser

+/- 15VDC

0-10VDC0/4-20 mA

0/4-20mA StatusI/O

Ioman Signal Handling System ( Optional)

110/220-240 VAC

CM IM001 OM001 DM016

RS232

LAN

Enviman ComVisioner

RS232, Alternative 1 RS232, Alternative 2 +3

RS232, Alternative 3

Plant DSC/PLC

RS232, Alternative 4 ( Cactus, ABDH, ModBus, Siemens 3964R, Comli)

COMMUNICATION ALTERNATIVES

STEEL PLANT APPLICATIONS

EMISSION MONITORING

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

• 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

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

REHEATING FURNACE

MONITORING AFTER REHEATING FURNACE

REHEATING FURNACESLABS

TAIL GAS DUCT

AR600 ( NO,NO2,NH3)

LD500 ( O2)

CORUS STEEL installation in European PlantInstalled early 2007Measuring NO,NO2,NH3,O2Temperature is approx. 450 degrees C

CORUS STEEL MEASUREMENT DATA

CORUS STEEL MEASUREMENT DATA

1100°C 1200 - 1300°C 1100°C

Charging zone

Preheating zone Heating zone Soaking zone

SLAB

dd

d d : Open-path height from SLAB surface 30 – 40mm

Cross section = 13 metre

= measurement location for Oxygen

POSCO STEEL, SLAB REHEATING FURNACE

Furnace duct1300 degrees C

Wall

Laser beam

LD500

RC101L+ PS

Max 85 degrees C

RE060L-T

50mm diam hole

Instrument air

Room temperature ( 15-30 degrees C)

Max temperature , 40 degrees C

Max 50 metre cable

CF120, max 1000 metre

MODIFICATIONS MADE FOR REHEATING FURNACE APPLICATION

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

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.

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)

Technical comparison

OPSIS

LD500

Separate TDL

Optical cable

Multiple TDL (4)

Switching TDL

Up to 8 paths I/O up to 255channels

RS232 with several ind.protocols

Modem

+Multiple path (max 8) +Multiple gas ( max 4)

+Also includes logger (IO256)

+Built-in cal.check

NEO TDL in the emitter Only 1 path I/O

RS232

+/-Simple system

- Limit in distance

-TDL on the duct

-Only one path

SIEMENS Separate TDL

Optical cable

Up to 3 paths I/O

RS232

+Multiple paths

+Built-in cal.check

BOREAL Separate TDL

Optical cable

Up to 8 paths I/O

RS232

+Multiple paths

Principle Paths Signal handling Comments (+/-)

Opsis LD500 TDL system features:Opsis LD500 TDL system features:

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

CONCLUSIONS