During 2022 CEM Solutions undertook a project to replace a maintenance intensive Continuous Emissions Monitoring Systems (CEMS) at a leading global chipboard wood manufacturing site.
The existing CEM system, which utilised a Hot Wet NDIR gas analyser, had been in continuous operation since 2013 and had performed generally well but did experience periodic breakdowns. Various external factors, such as poor compressed air quality, high ambient dust levels, and general wear and tear from years of operation further exasperated the situation which led to increased reliance on a redundant system.
After considering the successful performance on other sites with very similar processes, CEM Solutions decided to maintain a hot wet NDIR CEMS analyser and selected the notably reliable Dr. Foedisch MCA10 for the replacement. Initially, the plan was to retrofit the MCA10 to the existing CEMS panels. However, after discussions with the site, it was concluded that a complete upgrade of both the duty and redundant CEMS systems would be the best solution.
The previous CEMS system used a standalone heated sample pump, which operated efficiently for the entire duration but necessitated servicing every 3-6 months. In contrast, the MCA10 uses an injector and compressed air to draw a sample, eliminating the need for an external sample pump and resulting in reduced service requirements.
A visible weakness with the old CEMS system was with the sample lines, which were brittle and cracked due to UV degradation. CEM Solutions specified sample lines with additional silicone UV protection to prolong the life of the replacements. For improved performance, the previous 2-in-1 dust and flow probes were replaced with independent analysers: the Dr. Foedisch FMD09 flow probe and the Durag DR-808 dust probe, providing a proven method for monitoring of these components.
Incorporating a FID device into the system enabled the measurement of Total Organic Compounds (TOCs). To ensure safety, hydrogen monitors were installed in both CEMS panels, as the FID required a constant supply of hydrogen.
To counter the contaminated compressed air, additional filtration and dryers were installed to prevent any contaminated compressed air from entering the system.
The new CEMS system has already yielded several benefits:
- The MCA10’s remote connection capability has allowed CEM Solutions to dial in and monitor and report on the systems performance. This feature was invaluable during the commissioning stage, resulting in fewer visits to the site.
- The fully automatic QAL3 tests have eliminated the need for extensive involvement from site operators. This automation has instilled confidence that the tests are being conducted accurately and consistently.
- The user-friendly interface of the MCA10 has facilitated quick adoption by site operators. Basic training on the system has empowered operators to navigate through menus, check diagnostics, and perform essential tasks with confidence.
- The site successfully passed their QAL2 on all components, including dust and flow. This achievement validates the reliability and accuracy of the new CEMS system, reinforcing the effectiveness of the upgrade.
The key reasons for choosing the Dr. Foedisch MCA10 included its ability to perform automatic QAL3 tests, integrated O2 and FID measurement within the same system, and an operator-friendly touch screen interface with screen spec. Additionally, the MCA10 offered market-leading certified ranges for up to 12 gases, which satisfies any new or upcoming changes to environmental permits.
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If you believe that the MCA10 will be suitable for your business, please discover more here. If you have any questions or would simply like to know more on how we can help you, please contact our team today.