P r o d u c t i n f o rm at i o n

MERCEM

Continuous monitoring of mercury in flue

gases

Analyzers and Process Instrumentation

 Cutting mercury emission with a tried and
proven system – the SiCK MaiHaK MERCEM

The US EPA‘s Clean Air Mercury Rule issued in 2005 is the first rule worldwide which seeks to
reduce mercury emissions from coal-fired power plants. The limits for Hg measurement are in
the very low ppb levels. PS 12A defines the high performance standards for Continuous Mercu-
ry Monitoring Systems required under Part 60 and Part 75 of the CFR.
SICK MAIHAK is able to meet these high standards. MERCEM is a very accurate, field-proven
system that monitors Mercury in flue gas on a continuous basis.

features
¸ Continuous measurement of
total Hg in flue gas (both metal-
lic and ionic Hg)
¸ Easy handling and low mainte-
nance
¸ Reliable and robust technology areas of application
with years of field experience
¸ Proven wet conversion techno- ¸ Continuous emissions monito-
logy ring at power plants (coal, etc.)
¸ High-temperature gas sam- ¸ Waste incineration including
pling, 370 °F, no loss of mer- hazardous, chemical or sewage
cury species in the sampling sludge
system ¸ Cement production
¸ Proven even after FGD systems ¸ Ore processing, metal extrac-
(saturated gas streams) tion

Our Expertise And Experience For Your Benefit

2 MERCEM | SiCK MaiHaK

Proven +++ Efficient +++ Accurate +++ Stable

Proven Experience

¸ More than 10 years of field expe-

rience in continuous mercury
measurements in flue gases.
¸ More than 100 installations
demonstrating outstanding techno-
logical performance and operational
reliability.

Efficient Performance

¸ During combustion process, mercury

is released as a compound and in
elemental form. To obtain a compre-
hensive record of emissions, total
mercury content in the flue gas must
be measured.
¸ 100% efficient conversion of mer-
cury oxides to elemental mercury
through the use of the tin (II) chlo-
ride reduction technique.

accurate technique Stable measurement

¸ Detection of very low concentrations
can be achieved by adjusting the
duration of the enrichment process
(amalgamation). The measuring
range as well as the detection limit
can be varied and adjusted to meet
individual requirements.
¸ No spectral cross interference – the
mercury analyzer is not in direct con-
tact with the flue gas. This prevents
contamination from other flue gas
components.
¸ Using Cold Vapor Atomic Absorption
Spectroscopy (CVAAS) for analysis
¸ Very high zero stability – baseline
measurement is carried out during
every measurement cycle
¸ High span stability

SiCK MaiHaK | MERCEM 3

 Mercury analysis – an overview

the MERCEM operates either Built for easy access and

handling
• as stand-alone unit
The front door at the system cabinet
allows optimal access to all componen-
ts for operating and servicing purposes.
Measuring gas Data The ACE control unit and the MFU hea-
sampling acquisition ting controller are integrated as
19“ slide-ins into the door of the sys-
PC, Analog
data tem cabinet and can be accessed via a
separate transparent door. This means
MERCEM
Mercury the system can be operated without
Hg opening the cabinet door.

All components inside the cabinet can

Data transfer
Sample be easily accessed for servicing. The
reservoir for reaction solution is placed
just behind the front door for ease of
• in combination with the MCS100E HW replacement.
multi-component analysis system

OMD41
Continuous operation due to
Dust Data
acquisition
self-diagnostics

PC, modem In case of a malfunction the measuring

Probe1 system switches automatically into
modbus
“stand-by” mode and is flushed with an
PC, analog inert gas stream. For trouble-free ope-
Probe2 data ration of all system components, like
MERCEM
Mercury the reactor, the flow meter and the ana-
Hg * lyzer are checked automatically.

Data transfer MCS100E HW *

Sample
* Example of multi-component installation

Economic efficiency
The MERCEM can be closed coupled to the MCS100E HW multi-component CEM
system. This saves duplicate sample extraction equipment which reduces the
cost of ownership.

4 MERCEM | SiCK MaiHaK

 Sample preparation and analysis
Sample extraction
The sample pump draws the stack gas
into the system cabinet. All compo-
nents, e.g. sampling probe, tubes, etc.
that are in contact with the stack gas
are heated to 350 °F to avoid conden-
sation and corrosion.
Memory effects are minimized by the
high sample gas flow rate and high tem-
perature. A second pump extracts a par-
tial stream and feeds it to the mercury
measuring system.
Reduction
SnCl2 reaction solution is used to re-
duce the mercury compound to elemen-
tal mercury. Peristaltic pumps remove
excess condensation and add fresh re-
action solution. A cooler unit dries the
gas and removes remaining conden-
sate. The dried gas sample is fed into
the analyzer.
▸
Gas
sampling
▸
Port for external
calibration device
Reaction
solution
amalgamation discharge lamp with high stability, a
sample gas cell and a photo diode de-
The first step in the analyzer is the tector. The automatic baseline correc-
amalgamation procedure. A precisely tion before each measuring cycle en-
defined volume of the sample gas is sures the reliability of the
passed through a gold trap. The me- measurements.
tallic mercury is collected on the gold
trap by amalgamation. After the col-
lection period, all of the deposited
mercury is released by rapid heating
of the gold trap. The released mercu-
ry is carried into the cell of the pho-
tometer by an inert gas flow for mea-
surement by atomic absorption. The
analyzer is ready for the next measur-
ing cycle after a cooling period
Photometric measurement
Cold vapor-atomic absorption spec-
trometry (CVAAS) is used to measure
mercury. The single-beam photom- Gold trap Meas. gas cell
eter consists of a low pressure Hg-
Reactor Cooler
Analyzer
▸
▸
Photometer
Internal calibration
device
Gold trap
▸
▸
▸
Bypass
▸ Pump
Mass flow meter
SiCK MaiHaK | MERCEM 5
 System Control and interfaces
integrated data Storage
System
ACE 100 is an IBM-compatible compu-
ter in a 19” drawer with an illuminated
LCD and a membrane keypad. A silicon
disk offers mass storage capacity. The
ACE 100 controls the measurement se-
quence, calculates measured values,
monitors limit values and provides re-
sults, warnings and alarms for the inter-
nal display and the de-coupled fiber op-
tic interfaces. The keypad and monitor
are accessed easily behind the trans-
parent front door. An external keyboard
can be easily connected if required, for
e.g. servicing purpose.
display of measured values
and data back-up
All measuring and status data are dis-
played numerically, graphically or as a
concentration curve on the LC display.
Tracing the history of this data is pos-
sible due to the integrated mass sto-
rage disk.
 MERCEM | SiCK MaiHaK
Isolated interfaces, Easy-to-use Software
automatic range The software is easy to use, entries are
menu-controlled via cursor and func-
Data I/O is done via decoupled fiber-
tion keys. Two operating levels are
optic interfaces. Analog outputs (0/4-
available: one for measuring and one
20 mA), with optional automatic switch-
for servicing. Password protection en-
over mode for measuring ranges, and
sures optimal operating security.
status signals are generated here. It is
also possible to read in external digital
and analog data and process them. Se-
rial interface RS232, RS485 for Mod-
bus communication available.
¸ Meets specific demands of industrial measurement
systems
¸ Easy to use operating menu
¸ fail safe interfaces
Concentration curve Graphic display
 Technical data MERCEM
Hg CEMS
Measuring principle Photometry, cold vapor atomic absorption spectroscopy (CVAAS)
Measuring range Standard: 0 ... 10 µg/dscm (other ranges on request)
Cycle time Approx. 3 minutes
Detection limit Approx. 0.1 μg/dscm
Sample flow rate Approx. 16 LPM sampling system, 0.6 LPM for analyzer
Zero drift ≤ 5% of span or ≤ 1.0 µg/dscm (daily calibration error)
Span drift ≤ 5% of span or ≤ 1.0 µg/dscm (daily calibration error)
Maintenance interval Typically 4 weeks
Temperature influence <5 % of full scale/ ∆T = 35 °K
Auxiliaries required Instrument air: 34 LPM (peak), normal 6 LPM
N2: <1 LPM
SnCI2 solution: consumption: Typically 0.3 L per day, 10 L reservoir in system cabinet
Signal interfaces
Signal outputs ü 4 analog outputs, 0/4 - 20 mA; max. load 500 Ω max
ü 5 digital outputs, freely assignable (max. 250 VAC, 6 A)
ü Serial interface RS232, RS485, Modbus communication
Signal inputs ü 2 analog inputs, 4 - 20 mA
ü 11 digital inputs, freely assig. (bias reducing pot. 11 to 40 AC; low signal input resist. 2.2 k)
Power requirements ü 220 V / 60 Hz (2 phase – no neutral) for analyzer cabinet and for heated sample line
Power consumption ü Cabinet: max. 1900 Watts
ü Heated sampling probe: max 450 Watts
ü Gas sampling filter: max. 450 Watts
ü Heated sample line: 30 Watts/ft
Enclosure
Standard Free-standing general purpose cabinet, sheet steel RAL 7035
Dimensions (H x W x D) 83 x 31.5 x 24 inches (incl. 4 inch base)
Weight 750 lbs
Ambient conditions Temperature: +41 ... 100 °F
Humidity: 80 % max. non-condensing

SICK MAIHAK | Mercem 

 A N A LY Z E R S A N D P R O C E S S I N S T R U M E N TAT I O N
at H o M E i n t H E
INDUSTRIAL SECTOR
We can build on years of experi-
ence in the field of Analyzers and
Process Instrumentation. That is
why we are at home in the world
of cement and power plants
as well as in the chemical and
petrochemical sector. Be it emis-
sion control at waste treatment
or process optimization for steel
manufacturing, SICK MAIHAK
offers tailor-made solutions.
8011112/2007-06 · DIV03/BD · Printed in Germany (2007-06) · Subject to change without prior notice
All SICK products are accompanied by standard warranties and other terms and conditions
administrative Center
SICK MAIHAK Inc.
6900 West 110th Street
Minneapolis, MN 55438
Phone 952-941-6780
Fax 952-941-9287
WE OFFER YOU A CHOICE
SICK MAIHAK offers a number of
sensor-based techniques for anal-
ysis, ranging from the continuous
gas and dust measurement to
specialized applications for water
and liquid analysis. Within the
process measurement technol-
ogy SICK MAIHAK products play a
central role in determining volume
flow of gases and level of bulk
materials.
Systems Engineering and integration
SICK MAIHAK Inc.
15415 International Plaza Drive,
Suite 100
Houston, Texas 77032
Phone 281-436-5100
Fax 281-436-5200
AROUND THE WORLD TO SiCK GRouP
YouR SERViCE
Where ever you are, our global SICK MAIHAK represents the
network of subsidiaries and rep- process automation segment
resentatives is able to supply of the SICK group, one of the
qualified support when you need worlds leading manufacturer of
it. We deliver the equipment for intelligent sensors and sensor
your measuring tasks, provide solutions. With its 4,000 employ-
documentation and training. Our ees, SICK is able to offer an
highly skilled service staff offers extensive portfolio of products
support during installation, com- and services on the market of fac-
missioning and maintenance of tory and process automation.
the instruments. www.sick.com
information@sickmaihak.com
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Analyzers and Process Instrumentation