Implementation of Predictive

Emission Monitoring System

M Faiz Ishak, Process Control Engineer PC MTBE

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 Presentation Outline Topic covered today

Topic 1 Introduction
Introduction
Background Topic 3 Result
Problem Statement & Objective PEMS Implementation
Did you know? Success Story
Methodology
The rise of continuous monitoring Topic 2
CAR 2014 Regulation Solution to CAR 2014
Analogy Topic 4 Conclusion
Roadmap Conclusion
Comparison

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 Introduction
Key learning point for today

1. New Regulation introduced 3. Benchmarking of

under Environment Quality readily available Air
Act (EQA) 1974 so called Pollution Monitoring
Clean Air Regulation (CAR) System
2014

4. Chosen Air Pollution

2. Compliance Monitoring System
requirement to the
5. Achievement of the
regulation
chosen Air Pollution
monitoring system
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 Background
TOPIC #1: Introduction

Lilit Ikan

This presentation would be focusing on emission

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 Problem Statement & Objective
TOPIC #1: Introduction

Problem Statement Objective & Scope

Challenges in using To comply with all requirements stated in
unconventional method in Clean Air Regulation (CAR 2014)
achieving Malaysian
government regulatory
requirement (CAR2014)

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 Did you know?
TOPIC #1: Introduction

…one in eight of total global deaths- as a result of air

pollution exposure

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 The rise of emission monitoring
Topic #1: Introduction

Growth in emission monitoring CAR 2014

Many countries in the world
Industrial plant Regulation
have taken major steps to
are emitting tons enforcement
properly monitor and curb
of harmful gasses drive emission
emission. Industries need to
to the monitoring in
keep track of pollutant rate using
atmosphere. Malaysia
emission monitoring system

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 CAR 2014 Regulations
TOPIC #1: Introduction

to meet emission limits

to continuously monitor emission
to report continuous emission result to
DOE
These regulation shall apply to any industrial plant in Malaysia

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 Solution to CAR 2014
TOPIC #2: Methodology

There are 2 technologies for continuous

emission monitoring in market
1 2
Typical Alternative
CEMS solution PEMS to CEMS

Continuous Predictive
Emission Emission
Monitoring Monitoring
System System
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 CEMS is an analyzer system to continuously monitor emissions

CEMS

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 PEMS is a prediction system to continuously monitor emissions
using readily available process data

PLANT PUTRAJAYA
* Only during
modeling phase
MOBILE CEM-
CEMS* PIMS
DIS

NOx
DOE
SO2 Putrajaya
CO
Model DCS
STACK
PEMS

PROCESS

PEMS

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 Analogy
Topic#2: Methodology

Shopping

Continuous Monitoring
CEMS Analyzer
Continuous
PEMS Prediction Monitoring

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 Roadmap to solve CAR 2014
Topic#2: Methodology

Perform
EMSA Implementation DOE Malaysia
Certification &
reporting
CAR 2014
GAZETTED CEMS

PEMS
Identify
equipment
- boiler
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Emission Monitoring Situation Assessment (EMSA) is done in order
to check whether PEMS is technically viable to be implemented
Identify equipment
applicability
Install CEMS
No

No Emission
limit PEMS
violation Suitability Install PEMS
Assessment Yes

Yes

Install Air Pollution Control Upgrade CEMS/ Explore

Device PEMS suitability

No

Check No CEMS Yes

CEMS Suitability Modify CEMS
Condition Assessment
Availability No
of CEMS

Yes Yes
Maintain CEMS

Example EMSA Flowchart

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 Comparison
Topic#2: Methodology

DESCRIPTION CEMS PEMS

Type Hardware analyzer Predictive
Maintenance & Service Required Not required
Calibration EPA protocol gases Auto additional
calibration
Availability 95% if well maintained Approaching 100%
and service
Accuracy 99% if well Equal to CEMS
maintained
Spare part Required Not required

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 Comparison
Topic#2: Methodology

3,5 3,22
CEMS
3
CAPEX 2.35 Million RM
2,5 2,35
Annual OPEX 0.29 Million RM
Million RM

2 1,72 Total Cost Over 3 years

1,5
1,12 3.22 Million RM
1
0,5 0,230,20 PEMS
0 CAPEX 1.12 Million RM
CAPEX Annual OPEX Total Cost
over 3 years
Annual OPEX 0.20 Million RM
PEMS cost is almost 2x lower Total Cost Over 3 years
than CEMS 1.72 Million RM
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 PEMS Implementation Topic#3: Result

Mar 2015 Sep 2015 Oct 2015 Now

Development Certification Sustenance

1. PEMS application 1. Initial 1. Quarterly

to DOE certification test validation
(DOE) 2. Annual
2. Data Collection
2. Submit report certification
3. Modelling &
for DOE approval : Acceptance criteria for
Internal validation
PEMS audit test refer to US
4. PEMS configuration EPA PS-16 requirements

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 Success Story
Topic#3: Result

Compliance to Cost optimization of

Approval from Department
CAR 2014 1.4 Million RM of Environment Malaysia

Complied to CAR Cost optimization of Reference to other

since Oct 2015 PEMS installation PETRONAS unit
until now compared to CEMS interested with PEMS
installation Eg: PFK, ABF, PPT
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 Compliance to
CAR 2014
Complied to
CAR since Oct
2015 until now

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 Approval from
Department of
Environment
Malaysia Picture of Director General Department of Environment
Malaysia with CEO of Petronas Chemical MTBE and Head of
Group Technical Solutions

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 Conclusion & Path forward
Topic#4: Conclusion

Conclusion Path forward

A reliable and Negotiation to reduce
sustainable continuous validation requirement
emission monitoring from quarterly to
system was chosen and biannually for further
installed for 100% cost reduction by at
compliance to Clean Air least RM30,000
Regulation (CAR) 2014
requirement

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 THANK YOU

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