SmartCEMS® Syngas

Pyrolysis, Syngas plants and Biomass

The SmartCEMS® SynGas is a highly reliable monitoring system for Syngas applications and ensures reliable online continuous measurements of fuel gases composition (CO, CO2, O2, N2, CH4, and H2). This powerful stationary is extremely accurate and will be a valuable asset in Direct Reduced Iron (DRI) and other Syngas plants as they allow determining the quality parameters of blast furnace, coke and natural gas which are essential to process optimisation.

The SmartCEMS® Syngas was developped through an OEM with Madur (Poland) to enable easy compliance with the requirements of Environmental standards, CEMS codes and National Greenhouse and Energy Reporting (NGER). Designed to optimise performance/price ratio, the SmartCEMS® Syngas is small in size and measures with a very high level of accuracy. It is the cost effective alternative, for gas chromatograph for instance, in large and complex SynGas process control. Its powerful and pleasant PC interface provides operators and system integrators with a broad range of settings to adjust many aspects of the measurement tasks such as automated sampling, calibration, purge sequences, analogue outputs’ behaviour, data presentations…

Available as standalone unit, single analyser or redundant systems (fully backed up with manual and automatic redundancy) the SmartCEMS® Syngas is offered as a complete stationary CEMS for permanent installation or long term rental. AquaGas global service includes the various level of associated services (initial and final installation, commissioning, long term or punctual service agreement as well as the supply of consumables and critical spares for periods up to 5 years).

Brochure

Overview

SmartCEMS® Syngas Exclusive features

Continuous Online Monitoring of Syngas’ primary constituents CO, CO2, O2, N2, CH4, and H2	Ability to measure gas temperature, velocity and flow.
Powerful sensor combinations for complex gas matrices	Modular and flexible design with pleasant PC interface provide a broad range of settings to adjust many aspects of the measurement tasks such as automated sampling, calibration, purge sequences, analogue outputs’ behaviour.
Complies with international standards (EN14181, WA CEMS code, EPAs, NGER)	Semi-automatic or automatic redundancy for greater data availability and easy Data extraction and processing through Mcerts DAHS computer and CDAS software.
Easy operation and low maintenance required, no requirements for purge or zero gas.	Versatile selection of sample gas conditioning method incl. Peltier, Nafion, Compressor
Modular sampling train enabling optimal sampler transfer up to 90 metres sampling line	Cost effective alternative for large and complex Syngas Process Control (compare to Spectrometer or Gas Chromatograph)
Fully supported by AquaGas across Australia, New Zealand and the Pacific Islands (sales and services)	Available in IECEx for installation in Zone 1 explosive gas atmosphere Dossier of equivalence IECEx/ATEX for AHLX heated sampling train as per relevant Australian Standards.

SmartCEMS® Proprietary gas path/cell

The SmartCEMS® is an online monitoring systems designed for online measurement of SO2, CO, CO2, NO, NO2, VOC, CxHy, O2, for a large range of industrial applications including small to large combustion plants (power station, paper mill, cement plant…), WTE (waste to Energy) installations as well as Biogas, Syngas and Biomass generators. The combination of technologies (NDIR, TCD, PID, Electrochemical) and the addition of separate gas channels into the same instrument empower flexibility in multigas applications. A unique feature is to allocate a gas channel to sensible sensors. Its design ensures the cells have a limited exposure to gases and therefore extends considerably their respective life-time.

Optimised integration
The SmartCEMS® Syngas is a compact system delivered ready for installation. Thanks to its small size, the system is easy to locate, install and set-up. The routing of the cables and tubes to the instrument is simplified with all gas and electrical connections grouped onto a single interface plate.
Versatile
The SmartCEMS® Syngas sampling system configuration can be adapted to specific monitoring needs such as multipoint monitoring, redundancy, continuous or time set measuring cycles… When sampling from wet and hot gas, moisture content, condensates and salts are continuously removed by the use of one or several gas dryer(s) (Peltier or Nafion) equipped with built-in safety filter, condensate trap and safety inline particulate filters. Whether the SmartCEMS® Syngas uses the built-in sampling pump or the pressure from the source, the analyser is designed to work with overpressure. Single gas channel configuration can handle overpressure up 1.8 bar.
Pleasant interface
The SmartCEMS® Syngas’ pleasant PC interface provides operators and system integrators with a broad range of settings to adjust many aspects of the measurement tasks such as automated sampling, calibration, purge sequences, analogue outputs behaviour, data presentations… For large sites with complex monitoring requirements, the LAN and ModBus interfaces allow implementing in an efficient way large instruments networks with master/slave configurations and user settable monitoring functions.

SmartCEMS® Measured Gases

The SmartCEMS® offers multiple sensor and method configurations. Here are the measuring parameter for the most common gases. For other gases or different measuring ranges (MR), please consult us.

Gas & MR

Gas	Analysis Method	Range I Resolution	Accuracy	Time (T90)	Conformity
O₂ Oxygen	Electrochemical, Partial Pressure	20.95% \| 0.01%	± 0.1% abs. or 5% rel.	45 sec	ISO 12039, CTM-030
O₂ Oxygen	Electrochemical, Partial Pressure	25.00% \| 0.01%	± 0.1% abs. or 5% rel.	45 sec	ISO 12039, CTM-030
O₂ Oxygen	Electrochemical, Partial Pressure	100.00% \| 0.01%	± 0.1% abs. or 5% rel.	45 sec	ISO 12039, CTM-030
CO Carbon Monoxide	Electrochemical Sensor	4 000ppm \| 1ppm	± 5ppm abs. or 5% rel.	45 sec	ISO 12039, CTM-030
CO Carbon Monoxide	Electrochemical, with H2 compensation	4 000ppm \| 1ppm	± 5ppm abs. or 5% rel.	45 sec	ISO 12039, CTM-030
CO Carbon Monoxide	Electrochemical Sensor	20 000ppm \| 1ppm	± 5ppm abs. or 5% rel.	45 sec	ISO 12039, CTM-030
CO Carbon Monoxide	Electrochemical, with H2 compensation	20 000ppm \| 1ppm	± 5ppm abs. or 5% rel.	45 sec	ISO 12039, CTM-030
CO Carbon Monoxide	Electrochemical Sensor	10% \| 0.001%	± 0.005% abs. or 5% rel.	45 sec	ISO 12039, CTM-030
CO Carbon Monoxide	NDIR Non Dispersive Infra Red	10% \| 0.01%	± 0.05% abs. or 5% rel.	45 sec	EN 15058 and Method 10
CO Carbon Monoxide	NDIR Non Dispersive Infra Red	25% \| 0.01%	± 0.05% abs. or 5% rel.	45 sec	EN 15058 and Method 10
CO Carbon Monoxide	NDIR Non Dispersive Infra Red	50% \| 0.01%	± 0.05% abs. or 5% rel.	45 sec	EN 15058 and Method 10
CO Carbon Monoxide	NDIR Non Dispersive Infra Red	100% \| 0.1%	± 0.5% abs. or 5% rel.	45 sec	EN 15058 and Method 10
CO₂ Carbon Dioxide	NDIR Non Dispersive Infra Red	5% \| 0.01%	± 0.05% abs. or 5% rel.	45 sec	ISO 12039, OTM-13
CO₂ Carbon Dioxide	NDIR Non Dispersive Infra Red	10% \| 0.01%	± 0.05% abs. or 5% rel.	45 sec	ISO 12039, OTM-13
CO₂ Carbon Dioxide	NDIR Non Dispersive Infra Red	25% \| 0.01%	± 0.05% abs. or 5% rel.	45 sec	ISO 12039, OTM-13
CO₂ Carbon Dioxide	NDIR Non Dispersive Infra Red	50% \| 0.01%	± 0.05% abs. or 5% rel.	45 sec	ISO 12039, OTM-13
CO₂ Carbon Dioxide	NDIR Non Dispersive Infra Red	100% \| 0.1%	± 0.5% abs. or 5% rel.	45 sec	ISO 12039, OTM-13
C_xH_y Total Hydrocarbons	NDIR Non Dispersive Infra Red	1% \| 0.01%	± 0.05% abs. or 5% rel.	45 sec
C_xH_y Total Hydrocarbons	NDIR Non Dispersive Infra Red	5% \| 0.01%	± 0.05% abs. or 5% rel.	45 sec
C_xH_y Total Hydrocarbons	NDIR Non Dispersive Infra Red	10% \| 0.01%	± 0.05% abs. or 5% rel.	45 sec
C_xH_y Total Hydrocarbons	NDIR Non Dispersive Infra Red	25% \| 0.01%	± 0.05% abs. or 5% rel.	45 sec
C_xH_y Total Hydrocarbons	NDIR Non Dispersive Infra Red	50% \| 0.01%	± 0.05% abs. or 5% rel.	45 sec
C_xH_y Total Hydrocarbons	NDIR Non Dispersive Infra Red	100% \| 0.1%	± 0.5% abs. or 5% rel.	45 sec
NO Nitric Oxide	Electrochemical Sensor	1 000ppm \| 1ppm	± 5ppm abs. or 5% rel.	45 sec	CTM-022
NO Nitric Oxide	Electrochemical Sensor	5 000ppm \| 1ppm	± 5ppm abs. or 5% rel.	45 sec	CTM-022
NO₂ Nitrogen Dioxide	Electrochemical Sensor	1 000ppm \| 1ppm	± 5ppm abs. or 5% rel.	60 sec	CTM-022
NO₂ Nitrogen Dioxide	Electrochemical Sensor	4 000ppm \| 1ppm	± 5ppm abs. or 5% rel.	60 sec	CTM-022
SO₂ Sulphur Dioxide	Electrochemical Sensor	2 000ppm \| 1ppm	± 5ppm abs. or 5% rel.	45 sec
SO₂ Sulphur Dioxide	Electrochemical Sensor	5 000ppm \| 1ppm	± 5ppm abs. or 5% rel.	45 sec
H₂S Hydrogen sulfide	Electrochemical Sensor	1 000ppm \| 1ppm	± 5ppm abs. or 5% rel.	70 sec
H₂S Hydrogen sulfide	Electrochemical Sensor	10 000ppm \| 1ppm	± 5ppm abs. or 5% rel.	45 sec
H₂ Hydrogen	Electrochemical Sensor	2 000ppm \| 1ppm	± 10ppm abs. or 5% rel.	50 sec
H₂ Hydrogen	Electrochemical Sensor	20 000ppm \| 1ppm	± 10ppm abs. or 5% rel.	70 sec
H₂ Hydrogen	TCD Thermal Conductivity Detector	10% \| 0.1%	± 0.5% abs. or 5% rel	45 sec
H₂ Hydrogen	TCD Thermal Conductivity Detector	25% \| 0.1%	± 0.5% abs. or 5% rel	45 sec
H₂ Hydrogen	TCD Thermal Conductivity Detector	50% \| 0.1%	± 0.5% abs. or 5% rel	45 sec
H₂ Hydrogen	TCD Thermal Conductivity Detector	100% \| 0.1%	± 0.5% abs. or 5% rel	45 sec
N₂O Nitrous Oxide	NDIR Non Dispersive Infra Red	2 000ppm \| 1ppm	± 10ppm abs. or 5% rel	45 sec	ISO 21258
N₂O Nitrous Oxide	NDIR Non Dispersive Infra Red	5 000ppm \| 1ppm	± 10ppm abs. or 5% rel	45 sec	ISO 21258
CHF₃ Fluoroform (Refrigerant R23)	NDIR Non Dispersive Infra Red	2.5% \| 0.01%	± 0.05 abs. or 5% rel.	45 sec
CL₂ Chlorine	Electrochemical Sensor	250ppm \| 1ppm	± 5ppm abs. or 5% rel.	60 sec
VOC Volatile Organic Compounds	PID Photo Ionization Detector	100ppm \| 1ppm	± 5ppm abs. or 5% rel.	120 sec	Method 21
VOC Volatile Organic Compounds	PID Photo Ionization Detector	1000ppm \| 1ppm	± 5ppm abs. or 5% rel.	120 sec	Method 21

SmartCEMS®Syngas System Integration

The use of advanced online monitoring systems installed in the heart of Syngas processes usually requires integration of air conditioned analyser rooms or shelters to preserve the instruments from harsh plant conditions and corrosive atmospheres. The installation in an area protected from the weather also secures the data/instrument availability by providing permanent access to the analysers – if attendance is required for maintenance or diagnosis. Systems certified for installation in explosive area (ATEX) may be required in some cases.

Below is the two alternatives for the temperature controlled enclosure, the IP55 with air conditioning and the IP56 enclosure with fan forced:

IP55 Temperature Controlled Enclosure

IP55 enclosure with air conditioning unit. Enclosure fitted with terminals, gland plates, power point, circuit breaker and delivered ready for installation outdoor at industrial site.

Cooling Capacity	320 W
Compressor	Rotary piston compressor
Refrigerant	R134a / 1430
High/Low Pressure	20/13 bar
Temperature range	10°C ÷ 50°C
Air volume flow	Ambient 250 m3/h Cabinet 250 m3/h
Mounting	External recessed on enclosure side panel with SS cover
Weight and dimensions	13 kg – 520 x 270 x 110 mm
Mains fuse	6A required. 3,2A at start, max 1.8A / Power 375 W

IP56 Forced Fan Enclosure

Integration in standard IP56 enclosure with forced fan. Enclosure fitted with terminals, gland plates, power point, circuit breaker and delivered ready for installation outdoor at industrial site.

SmartCEMS®Syngas Sampling System

Stationary Gas Sampling Probe

The SmartCEMS® Syngas‘ stationary gas sampling probe has a modular design to fit most of CEMS and Process applications. The Probe configuration can be adapted to the sampling conditions and environment (gas temperature, dust load…). The SmartCEMS® Syngas‘ stationary Gas sampling probe features insitu sintered stainless steel filter, Gas temperature measurement with K-type thermocouple, backflush valve (manual or automatic)to blowback the filter. The SmartCEMS® Syngas‘ stationary gas sampling probe is typically flange mounted directly onto the sampling duct. Once extracted the sample is then directed to the gas conditioning system through heated or unheated sampling line.

Stationary Gas Conditioning Unit

The SmartCEMS® Syngas GF4 Gas Conditioning unit is designed for continuous removal of tars and condensate from raw Syngas.

MD3 Gas Conditioning Unit

The SmartCEMS® Syngas‘ MD3 Gas Conditioning unit is equipped with a condensation dryer based on the Peltier element, built-in peristaltic pump for condensate removal, and large surface particulate filter. The SmartCEMS® Syngas‘ MD3 gas dryer can be supplied mounted onto the same plate than the SmartCEMS® gas analyser or mounted on its own plate with its associated power supply. This allows locating the SmartCEMS® Syngas‘ MD3 gas conditioning unit located directly at the sampling point.

Gas Multiplexer

The SmartCEMS® Gas multiplexer enables sequential monitoring of multiple gas streams. With user configurable sampling sequences, the SmartCEMS® multiplexer provides plant operators with the ability to scan Syngas composition across various hydrocarbons gas streams and process locations.

SmartCEMS® Syngas Configurations

SmartCEMS® Compact Configuration

1. Stationary gas sampling probe with optional heated filter, insitu filter and backflush

2. Heated sample line (1 to 5m)

3. SmartCEMS® Multigas Analyzer with MD3 gas conditioning system with Peltier cooler, peristaltic pump and particulate filter with optional IP55 housing.

SmartCEMS® Split Configuration

1. Stationary gas sampling probe with optional heated filter, Insitu filter and backflush

2. Heated Sample line short (1 to 3m)

3. MD3 gas conditioning system with Peltier cooler, peristaltic pump and particulate filter installed near the sampling probe assembly and integrated into the AC housing.

4. Dry gas and electric connection cable. Connects gas dryer and SmartCEMS® . Dry gas line can be long, distance up to 100m or longer if necessary.

5. SmartCEMS® Multigas analyser installed in convenient location (e.g. operation shed), may be in remote distance from measurement place. Option available with the IP55.

SmartCEMS® Twin-Split Configuration

1. Stationary gas sampling probe with optional heated filter, Insitu filter and backflush

2. Heated Sample line short (1 to 3m)

3. MD3 gas conditioning system with Peltier cooler, peristaltic pump and particulate filter installed near the sampling probe assembly and integrated into the AC housing.

4 . Dry gas and electric connection cable. Connects gas dryer and SmartCEMS®. Non-heated line can be up to 100m or longer if necessary.

5. SmartCEMS® Multigas analyser installed in convenient location (e.g. operation shed) with optional IP55 housing

SmartCEMS® Mixed Configuration: Twin-Split compact with remote dryer

1. Stationary gas sampling probe with optional heated filter, Insitu filter and backflush

2. Heated Sample line short (1 to 3m)

3. MD3 gas conditioning system with Peltier cooler, peristaltic pump and particulate filter installed near the sampling probe assembly and integrated into the AC housing.

4 . Dry gas and electric connection cable. Connects gas dryer and SmartCEMS®. Non-heated line can be up to 100m or longer if necessary.

5. SmartCEMS® Multigas analyser installed in convenient location (e.g. operation shed) with optional IP55 housing

Fully Supported in Australia, New Zealand and Pacific Islands

AquaGas Pty Ltd ensure providing support across the Oceania region for maintenance and supply of spares (both hardware & software) as required for the installed system for a minimum period of 20 (twenty) years i.e. the design life of the plant, after successful commissioning of the system.

Depending on your needs, AquaGas Pty Ltd provides adapted services and a technical solution to incorporate Automatic Monitoring Systems (CEMS, AQMS, WQMS, Process Analytics, Gas Detection…) into the mainstream of your existing system or new installation:

Installation supervision

Final installation

Parameterization

Start-up operation

Site acceptance testing and performance testing

System certifications and RATA relative accuracy test audit

Flexible and customised service agreements available on all equipment supplied:

Accomplishment of preventive and corrective maintenance with pre-set site attendance time

Dedicated technician

Email and phone support – remote access

Supply of spare parts

Asset management

Instrument network handling:

Maintenance plan

Implementation of certification and calibration programs

Development of data processing systems

Spare parts stock and system documentation management

Gas cylinder stock handling

SmartCEMS® – Tailored to TODAY’s CEMS requirements

Typical Applications

Process gas and emissions monitoring in combustion plants, boilers, syngas, biogas, waste recycling facilities (Waste to Energy) and associated filtration systems are typical applications for the SmartCEMS® multiple gas channels configuration.

Landfills

“Landfilling” is the main method for disposal of municipal and household solid wastes or refuses in Australia. Although maintained in an oxygen-free environment and relatively dry conditions, landfill waste produces significant amounts of landfill gas (mostly methane). The Mamos enables process and air pollution emissions monitoring from solid waste landfills. Landfills operations require the control of methane CH4 and non-methane organic compound emissions (NMHC) emitted as well as an accurate online monitoring of the gas composition (CH4, CO, CO2, H2, H2S and O2). This effectively requires the collection and combustion of landfill gases. So, a good solution to the landfill gas problem is to collect it and use it to produce electricity. Landfill gas (LFG)entering the gas sampling system is saturated with water, and that water must be removed prior to further processing. The typical dry composition of the low-Btu gas is 57% CH4, 42% carbon dioxide, 0.5% nitrogen, 0.2% hydrogen, 0 to 1000 ppm of H2S and 0.2%oxygen. In addition, a significant number of other compounds are found in trace quantities. These include alkanes, aromatics, chlorocarbons, oxygenated compounds, other hydrocarbons and sulfur dioxide.

Biogas Plants

In biotechnological processes, the detailed monitoring of the fermentation product, in this case biogas, provides valuable information. Therefore, it is recommended to monitor both the volume of gas produced and the gas composition. With regard to process monitoring, a change in either gas production or gas composition can be an indicator of process imbalance.

Biogas primary constituents

CH4 and H2S measured during the methanation process give a good overall view of the performance of the degradation process and bacterial activity. A decrease in methane content can be a first sign of organic overload, provided that the feedstock mix has not recently changed. Similarly, a sudden increase in H2S can provoke process instability.
Simultaneous real-time monitoring of CH4, H2S and CO2 empower process automation (i.e. operation of scrubbers)
Before entering the distribution chain, the product must be qualified, again for economic reasons (excess H2S and/or CO2 in the CH4 would make it ‘sour’ and potentially corrosive enough to damage distribution infrastructure)
CH4, H2S, CO, CO2 and O2 Continuous Stack Emissions Monitoring required for environmental compliance

Gas Treatment Centres

Accuracy and high reliability in harsh conditions of operations makes the SmartCEMS® a powerful optimisation tool for waste recycling facilities (incinerator, water treatment plant).

SCR and SNCR Selective non-catalytic and catalytic reductions are designed to reduce the emissions of NOx by injecting ammonia is directly injected at the combustion chamber exhaust. This process causes the nitrogen oxides to react with the ammonium and turn into nitrogen and water. The SmartCEMS® is suited to upstream and downstream SNCR/SCR monitoring and provides plants operator with accurate data to control NOx regulatory emissions while optimising the denitrification process with upstream NOx measurements.

GTC and flue gas scrubbers reduce the emissions of acid gases such as SO2 with pulverised lime powder or solutions while the discharge of heavy metals and organic pollutants is controlled with the addition of activated carbon. Online monitoring of O2, SO2 upstream of the GTC allows reducing the quantity of reagents injected.

Syngas Plants

The use of online monitoring systems for processed gas at locations such blast furnace gas outlet, converter off gas exhaust and coking gas outlet is very reasonable in order to analyse the fuel gases composition by measuring the concentration of CO, CO2, O2, N2, CH4, and H2. There from the calorific value BTU and the Wobbe Index WI can be accurately calculated. Modern steel plants uses dedicated stationary online monitoring system to monitor the primary constituents of Direct Reduction Iron process gases essential to have a full understanding of the process status and efficiency.

SmartCEMS® Syngas

SmartCEMS® Syngas Exclusive features

SmartCEMS® Proprietary gas path/cell

Optimised integration

Versatile

Pleasant interface

SmartCEMS® Measured Gases

SmartCEMS®Syngas System Integration

IP55 Temperature Controlled Enclosure

IP56 Forced Fan Enclosure

SmartCEMS®Syngas Sampling System

Stationary Gas Sampling Probe

Stationary Gas Conditioning Unit

MD3 Gas Conditioning Unit

Gas Multiplexer

SmartCEMS® Syngas Configurations

SmartCEMS® Compact Configuration

SmartCEMS® Split Configuration

SmartCEMS® Twin-Split Configuration

SmartCEMS® Mixed Configuration: Twin-Split compact with remote dryer

Fully Supported in Australia, New Zealand and Pacific Islands

SmartCEMS® – Tailored to TODAY’s CEMS requirements

Typical Applications

Landfills

Biogas Plants

Gas Treatment Centres

Syngas Plants

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