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Sulphuric Acid

Production

Internationally approved

Continuous Emissions Monitoring


and Process Control

A6

Continuous Emissions Monitoring and Process


Control in Sulphuric Acid Production

The process control of a sulphuric acid plant needs good


and reliable detection of gas phase SO2. To measure SO2
is a challenge due to the corrosive environment and high
concentration of SO2.
Several places in the process needs to be monitored
and to transport the sample gas is difficult. A large dynamic range is needed as the SO2 concentration can vary
between 15% volume and a few mg/m3.
Most systems installed need a lot of maintenance,
sometimes as often as every day.
The Opsis DOAS system is different and provides sulphuric acid plants with an accurate analyser that will operate with a minimum of maintenance.
A typical service interval with an Opsis system is 3
to 6 months. The Opsis DOAS system is a non-contact
method, using an optical measurement path that operates across a duct. The optical light is transported in an
optical fibre to the analyser and one analyser can operate
several paths.
Besides the measurements of SO2, additional gases
such as SO3, H2O and O2 can be measured.

Receiver
Emitter
Fibre optic cable
Power
supply
Stack

Analyser cabinet

An Opsis system layout for monitoring in a sulphuric acid production


plant

Test and Approvals


The Opsis System has been tested and approved by a
number of internationally recognized institutes and authorities. The system meets the European directive for
power plants and is approved by German TV, British
MCERTS and U.S. EPA. Full details are available on request.

Return of Investment

Opsis Product Portfolio

The cost of investing in an Opsis DOAS system, to measure SO2 and other gases, is small compared to the amount
of money that can be saved by having better control of
the process. The cost of the Opsis DOAS system is also
small compared to the amount of money that are spent on
maintaining old systems based on extractive techniques.

Opsis has a full product portfolio for measurements of


gases in a sulphuric acid production plant. It includes
systems for continuous emissions monitoring, process
control as well as for air quality monitoring. The total
solution also includes highly skilled service and support.
For further information, please visit www.opsis.se.

Please contact your Opsis supplier to discuss your particular system requirements, including the compounds you
wish to monitor. Separate product and other industrial application sheets are available.
Specifications subject to change without notice

Heater

Sulphur feed

Furnace

Contact unit

1
Mixing
chamber

Heat
exchanger

Stack

Opsis Monitoring Paths

1.
2.
3.
4.
5.

6.

SO2: 020% Vol.


SO2: 020% Vol.
SO2: 02% Vol.
SO2: 02500 ppm
NO: 0500 ppm
NO2: 0100 ppm
SO2: 01000 ppm
SO2: 020% Vol.

Heat exchanger
Heat
exchanger

3
5

Conc.
SO2 unit

Cooler

4
SO3
absorption
unit

Drying
tower

Peroxide
scrubber

Final
absorption
tower

First
absorption
tower

A schematic drawing of a sulphuric acid production plant including the SO2 and NOX measurement spots of the Opsis monitoring system

Performance Data (typical data which may vary depending on application)


Lowest TV
approved
measurement
range

Min. detectable
quantities
(monitoring path
1 m, measurement
time 30 sec.)

Zero drift
(1 m path,
max. per
month)(3)

Span drift
(per month,
better than)

Linearity
error
(of measurement
range,
better than)

Hardware
Max. length of
fibre optic cable requirement
(when
monitoring
individual
compounds)(4)

AR600/AR620 Analyser
SO2 emission 05000 mg/m3
SO2 process 0100% Vol.
SO3(1)
01000 g/m3
NO(2)
02000 mg/m3
NO2
02000 mg/m3
H2O
0100% Vol.
Hg0
01000 g/m3

080 mg/m3


0150 mg/m3
020 mg/m3
030% Vol.
0150 mg/m3

1 mg/m3
0.1% Vol.
0.3 g/m3
1 mg/m3
1 mg/m3
0.1% Vol.
3 g/m3

2 mg/m3
0.2% Vol.
0.6 g/m3
2 mg/m3
2 mg/m3
0.2% Vol.
6 g/m3

2%
2%
2%
2%
2%
2%
2%

1%
1%
1%
1%
1%
1%
1%

100 m
200 m
100 m
10 m
200 m
100 m
50 m

AR600/620
AR600/620
AR600/620
AR600/620
AR600/620
AR620
AR600/620

AR650 Analyser
SO2
01000 g/m3
SO3
01000 g/m3
CO
010000 mg/m3
H2O
0100% Vol.
CO2
0100% Vol.



075 mg/m3
030% Vol.

30 mg/m3
30 mg/m3
3 mg/m3
0.1% Vol.
0.1% Vol.

60 mg/m3
60 mg/m3
6 mg/m3
0.2% Vol.
0.2% Vol.

2%
2%
2%
2%
2%

1%
1%
1%
1%
1%

10 m
10 m
10 m
100 m
50 m

AR650
AR650
AR650
AR650
AR650

0.1% Vol.
0.1% Vol.
0.1% Vol.
0.1% Vol.
0.1% Vol.
10C

0.2% Vol.
0.2% Vol.
0.2% Vol.
0.2% Vol.
0.2% Vol.
20C

2%
2%
2%
2%
2%
2%

1%
1%
1%
1%
1%
1%

500 m*
500 m*
500 m*
500 m*
500 m*
500 m*

LD500
LD500
LD500
LD500
LD500
LD500

Compound

Typical
measurement
range

LD500 Laser diode gas analyser


CO
0100% Vol.

CO2
0100% Vol.

H2O
0100% Vol.

H2S
0100% Vol.

O2
021%

Temperature 01400C

Maximum SO2 concentration 500 mg/m3m


Maximum SO2 concentration 5 g/m3m
(3)
For AR650 the same values are valid as maximum zero drift per year.
(4)
When monitoring several compounds, the shortest fibre optic cable given by
the set of components (refer to product sheet P9) has to be used.
(1)
(2)

Besides the compounds above, the Opsis system monitors the following gases:
hydrogen bromide (HBr), bromine (Br2), iodine (I2), hydrogen cyanide (HCN),
hydrogen sulphide (H2S), phosgene (COCl2), and others.
* Laser and communication cables.
Recommended monitoring path length: 1 to 5 m
After wet scrubbers or when the particulate concentration is high, the monitoring path length may have to be reduced.

Continuous Emissions Monitoring


and Process Control

Why Opsis?
High-performance, cross-stack monitoring
Multi-gas and multi-path system
No sampling required, non-contact measurement system
Operates with a minimum of maintenance
Internationally approved
Hundreds of systems installed worldwide

OPSIS AB
Box 244
SE-244 02 Furulund, Sweden
Telephone Int +46 46 72 25 00
Telefax Int +46 46 72 25 01
E-mail info@opsis.se
URL http://www.opsis.se

2012 06

A6

OpsisAB/ Tempte& TempteAB/Grahns TryckeriAB, 2012

Experienced and skilled service network