(85d) Real-Time Gas Cloud Mapping for the Chemical Industry

Gas leaks involving toxic or flammable substances are a significant and often underestimated risk in the chemical industry. Statistics show that almost 70% of significant gas leaks go undetected by conventional gas sensors. Once in the air, accurately tracking the location, spread and movement of gas clouds using conventional methods becomes extremely difficult.

Grandperspective GmbH, an emissions monitoring company, uses hyperspectral imaging based on Fourier Transform Infrared (FTIR) remote sensing technology. This advanced remote monitoring system provides early warning of hazardous gas emissions and continuous detection of even the smallest leaks over long periods of time.

This case study illustrates the use of Grandperspective's scanfeld® solution at the site of a multi-national petrochemical company. Initially installed for targeted monitoring during a plant turnaround, the system was later expanded to cover the entire site. The primary objective was to detect ethylene and other compounds while evaluating the performance of the system against other established technologies.

Our presentation will explore the value of 24/7 area monitoring at this specific plant and demonstrate how continuous monitoring of fugitive ethylene emissions – across varying weather conditions and process states – enables operators to identify trends and optimize plant performance. We will highlight real-world incidents, including the detection of a methane and ethylene leak during a plant turnaround and start-up, which significantly reduced subsequent maintenance costs by enabling immediate countermeasures to be taken.

We will also discuss the impact of extending the monitored area during normal operations, which resulted in the detection of an unknown ethylene leak with a flow rate of approximately 300L/h from a distance of 300 meters. Whilst handheld devices were unable to pinpoint the exact location of the leak, the rapid and detailed data provided by the scanfeld® system enabled timely identification and repair. Ethylene leaks with rates exceeding 10g/h can be detected in real time within line of sight, while smaller leaks can typically be identified within a day – a significant improvement on the up to six weeks required without continuous monitoring.

These examples highlight how unplanned maintenance due to undetected leaks can cost operators up to five times more than planned maintenance, emphasizing the essential value of real-time monitoring.