Procal 2000 IR Emissions Analyser

Procal 2000 IR Emissions Analyser
In-situ, multi-component IR emissions analyser

Low cost of through-life ownership
Proven success in over 2600 applications worldwide
Kittiwake Procal Ltd

A Kittiwake Group Company
Instrument Overview
Procal 2000 is an infra-red (IR), duct or stack-mounted Procal 2000 uses the reflective beam principle to directly
analyser, designed to provide In-Situ analysis of up to six gas- measure process gas as it enters the in situ sample cell. Unlike
phase emission components. higher maintenance extractive systems, Procal’s patented,
sintered metal technology removes the need for gas filtering or
A typical system comprises a stack mounted analyser, an sample conditioning.
integral calibration function and a Control Unit with options
which include a powerful in situ Heater and a stand-alone The Procal 2000 analyser requires very little maintenance
Analysis Software package. and achieves a class-beating up-time of over 98% in
demanding applications.
The Control Unit can support multiple analysers from the Procal range
Examples of Principles of Operation

Analyser: The Procal 2000 analyser operates on the proven, Auto Verification: The integral Auto Verification Unit initiates
single beam, dual–wavelength IR light principle. Mid IR Pulses, a zero-check on the system by filling the sample probe with
at two specific wavelengths per monitored component, are clean, dry instrument air. Similarly, it performs a span-check by
transmitted through the sample cell. The ‘measure’ pulse is filling the sample probe with certified span gas.
partially absorbed by the gases being measured while the
‘reference’ pulse remains unaffected. Up to eight wavelengths Applications:The Procal 2000 analyser has been in service for over
are available, sometimes sharing reference wavelengths, 25 years with continual product improvement to match ever-
allowing up to six gas-phase component concentrations to be tightening legislative requirements. Over 2,600 Procal 2000 units
monitored simultaneously. Uniquely, the operation, zero and are in operation worldwide - refer to our industry data sheets
calibration are “fully challenged” in that all operating modes or visit www.procal.com for typical applications and associated
use the same optical path and system components. measurement ranges.
Features Benefits
Multi-component gas analysis Each Procal 2000 can measure up to six components.
Direct in-situ measurements No requirement for high cost, high maintenance sample handling
system or sample conditioning.
Wet or dry (option) Can report on Wet or Dry gas basis (option).
Automatic signal verification and recalibration No operator intervention during routine use.
Oxygen or CO2 measurement normalisation (option) Report measurement corrected to normalised O2 or CO2 reference
conditions.
Flange mounted analyser Reduced cost and simple of installation.
Low maintenance Reduced cost of through life ownership
ATEX / IEC option. Can be used in hazardous areas.
Examples of Monitoring Ranges

Principle of operation: Single Beam Dual Wavelength Infra Red with GFC where advantageous
Gases measured: Up to 6 hetero-atomic molecular gases as determined by the application.
CO 0 - 200ppm / 250mg/Nm3 CO2 0 - 15%

SO2 0 - 100ppm / 280mg/Nm3 H2O 0 - 12%
3
NO 0 - 300ppm / 400mg/Nm
530 (20.9”) 830 (32.7”) *

390 (15.4”) Insertion Length
Mounting Flange
380
(15”)
190.5 85
4 x M16 Studs equispaced
(7.5”) (3.35”) on 152.4 (6”) PCD 135
(5.3”)
180
125 Mounting Flange 12.7 (7.1”)
(4.92”) (0.5”)
All measurements are in Millimeters * Probe material SS 316 L
Control Unit Options
Analyser Control Unit - Procal 1000 series

The Procal 1000 data logging and control system is Microsoft Windows based.
The system is capable of controlling up to six, widely dispersed, Procal analysers of any design.
The Procal 1000 series is also designed to accept signal I/O from other instruments in the
process to provide a single CEMS data hub. The Procal 1000 displays gas concentrations and
third party analyser I/O along with information on sample conditions, diagnostic data and
trends. The information can also be made available to external components in a variety of
industry standard data protocols.
Specifications & Installation
Spectral range: Specific application dependent wavelengths (up to 8) are selected between 2-12μm
Infra-red source: Enclosed nichrome filament.
Infra-red detector: Solid state pyroelectric element.
Sample path length: 1 metre
Sample temperature: Up to 350°C (660°F) (higher temperatures on application)
Cross-sensitivity: Minimal due to the wavelength selection and advanced algorithms in the processor software.
Accuracy: Typically ±2% of full scale concentration but dependent on application.
Response time: Application dependent but typically 120 seconds to T90.
Enclosure: Aluminium alloy casting with high protection finish, protected to IP65 (NEMA 4X)
Operating Environment: Operating temperature range -20°C to 55°C (-4°F to 130°F).
Optional Analyser Cooler/Heater for greater temperature range.
Materials-contact with gas: Calcium Fluoride, Glass, 316 Stainless Steel, Graphite.
Services required: Power for analyser 115V/230V 100W
Power for in situ heater (optional) 115V/230V 1kW
Instrument air for the analyser void purge, auto zero and sample cell protection, controlled by the
analyser, 2 barG; flow rate 0.5 litre/min constant and 6 litre/min intermittent during Auto-zero
(typically 8 minutes every 12 hours).
Interconnection cable: 2 twisted-pair cores with individual screen typically allows up to 1200m separation between Analyser
and Procal 1000 Analyser Control Unit.
Weight: 21 kg (46.3lb).
Physical Dimensions: Analyser 1360mm (53.5”) x 380mm (15”) x 315mm (12.4”)
Optional Components
Optional accessories are available to extend the analyser’s capability in cases of extreme process or ambient variations. Typical
examples would be a probe heater to ensure the in situ gas cell operates above process gas dew point, a gas flow bypass for
high thermal stress applications and a head cooler for operation in high ambient temperature conditions. Further details of these
and many other accessories are available at www.procal.com or on the accessories data sheet.
Approvals
Continuous Emissions Monitoring The Procal 2000 system is designed to meet the requirements of both customers and
CEM - US EPA 40 CFR part 60 & 75 environmental authorities worldwide. The system enables rapid upgrades with regard
AMS - Europe QAL 3 of EN 14181 to measuring range, presentation and reporting format, thus ensuring compliance
with reporting criteria such as US EPA 40 CFR part 60 & 75 legislation. The system
calculates errors due to drift in Zero & Span Calibration before correction as required
for QAL 3 of EN 14181.
Kittiwake Procal Ltd Tel: +44 (0) 1733 232495

5 Maxwell Road Fax: +44 (0) 1733 235255
Peterborough
PE2 7HU sales@procal.com
United Kingdom www.procal.com
7-3222-02

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Procal 2000 IR Emissions Analyser

In-situ, multi-component IR emissions analyser

Kittiwake Procal Ltd

Examples of Principles of Operation

Examples of Monitoring Ranges

CO 0 - 200ppm / 250mg/Nm3 CO2 0 - 15%

530 (20.9”) 830 (32.7”) *

All measurements are in Millimeters * Probe material SS 316 L

Control Unit Options

Analyser Control Unit - Procal 1000 series

Kittiwake Procal Ltd Tel: +44 (0) 1733 232495

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