Industrial CEMS Deployment — Major Petrochemical Facility
End-to-end deployment of a Continuous Emission Monitoring System across six stacks at a major UAE petrochemical plant, achieving full MOEI compliance within 90 days.
Project Overview
A leading petrochemical operator required a fully compliant CEMS solution capable of simultaneously monitoring SO₂, NOₓ, CO, CO₂, O₂, and particulate matter across six independent stacks — all within a 90-day compliance deadline set by the Ministry of Energy & Infrastructure.
The Challenge
The client operated legacy analysers across multiple buildings with no centralised data acquisition. Corrosive process gases, extreme ambient temperatures (up to 55 °C), and site congestion made retrofit engineering a significant challenge. A previous vendor had failed to deliver within a prior compliance window, leaving the client facing potential regulatory action.
Our Solution
EnviPro designed a multi-stack CEMS architecture using SICK MCS100E hot-wet analysers and paired each stack with a dedicated sample conditioning unit. A central SCADA system was integrated with the plant DCS, providing real-time dashboarding and automated compliance reporting. All installation, cabling, and commissioning was performed by our in-house team, eliminating sub-contractor delays.
Results
Full MOEI compliance was achieved in 78 days — 12 days ahead of schedule. System uptime in the first six months exceeded 99.4 %. The client avoided an estimated AED 2.4 million in potential fines and has since extended the scope to two additional process units.
“EnviPro delivered where others could not. Their engineering rigour and on-site responsiveness gave us complete confidence throughout the project.”