Continuous Emissions Monitoring System for a Glass Plant – ATEX Project
Identified Challenge
The client, an industrial glass manufacturer, needed to carry out a major revamping of its electric furnace, including the installation of a new chimney and a modern Continuous Emissions Monitoring System (CEMS).
The new CEMS had to measure the main pollutants and physical parameters: SO₂, NO, NO₂, O₂, dust, flow rate, and temperature. The entire system had to be supervised by a SCADA compliant with European and Italian regulations.
A key challenge identified during the project concerned the ATEX classification of the area adjacent to the chimney, which was classified as a hazardous zone according to the Ex directive.
Solution:
Opus Automazione designed and implemented a sampling and analysis system fully compliant with Ex II2G T6 standards, addressing all the complexities of the installation environment.
The main technical actions carried out included:
Design and construction of a continuous sampling system suitable for ATEX-classified areas.
Selection and installation of Ex-proof instruments on the chimney.
Placement of analyzers inside a shelter with pressurized electrical panels, ensuring operational safety.
Custom gas treatment to neutralize the SO₃ component, which is highly corrosive to instrument cells and optical components.
Installation of DatiSME software, compliant with current regulations, on three different workstations: local, environmental manager, and plant management.
Project completion with commissioning, final testing, and operator training.
Results Achieved:
ATEX compliance ensured:
The entire CEMS was designed to operate in hazardous areas, fully complying with Ex II2G T6 standards, ensuring installation safety.Protection of analyzers from SO₃:
The preventive maintenance service minimizes the risk of failures or malfunctions, ensuring stable and environmentally compliant energy production.Immediate operability and personnel training:
On-site training and final testing enabled a smooth commissioning process, reducing system startup times.Centralized supervision and traceability:
The dedicated SCADA system provides real-time supervision and complete traceability of all key parameters.
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