3rd october 2014 cemtek user group meeting abb analytical
TRANSCRIPT
Cemtek User Group MeetingABB Analytical Measurement
3rd October 2014
Introduction
Steve GibbonsBusiness Development Manager – CEMS
ABB Inc. (Measurement Products)Tel: +1 (215) 292-8589
Email: [email protected]
Agenda CEMTEK / ABB relationship ABB Continuous Gas Analyzers Overview of select few products LGR Off-Axis ICOS technology Applications for Off-Axis ICOS Questions?
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CEMTEK / ABB relationship
CEMTEK Contracted ‘System Integrator’ since March 2014
Certified service partner
Customer focused
Responsive and skilled service organization
Capable/active to introduce ‘new’ technologies – e.g. OA-ICOS
ABB Extensive product portfolio…
GC, FTIR, NDIR, NDUV, PMD, TCD, FID, Zirconia, TDL, OA-ICOS …
…serving all major industriesOil, Gas & Petrochemicals, Chemicals, (Power), Cement, Iron & Steel, Pulp & Paper, Glass, Aluminum, Pharmaceuticals, Marine …
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ABB Continuous Gas AnalyzersFormerly ‘Hartmann & Braun’Established 130 years ago
1938 – First Usable NDIR-Process-Spectrometer
Karl LuftErwin Lehrer
The defining moment of non-dispersive infrared photometers came from Erwin Lehrer and Karl Luft.
Two product linesAdvance Optima and EasyLine
Price
Perf
orm
ance
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Advance OptimaAvailable analyzer modules
IR Photometer
Uras26
Paramagnetic Oxygen
Magnos206
Thermal Conductivity
Caldos27
Trace Oxygen
ZO23
UV / IR Photometer
Limas11
Thermal Conductivity
Caldos25
Flame-ionization detector
MultiFID14 (NMHC)
Paramagnetic Oxygen
Magnos27The Advance Optima series is based on an integrated system concept
Standardized analyzer modules can be combined to a multi-analyzer system
via
Eth
erne
t
Tunable Diode Laser
LS25
Advance OptimaInnovative modular analyzer technology
Common system controller
Measures up to 6 gas components
One central unit - 4 analyzer modules
Analyzers can be operated at a distance of 350 m from the central unit
Sample conditioning system signals can also be integrated on network
Internal PLC functionality- Valve control – autocal, stream switching- Calculations – O2 correction, Wet to Dry- Integrate external signals- Cross sensitivity correction- Program soft keys (i.e. shortcuts)
350 m
Module 1
Module 2 Module 3
Module 4
Module 1
Module 2 Module 3
Module 4
Practical Applications
Simplified system integration Minimize hard-wired cabling = time and cost savings Common spare parts
Internal correction / calculations For example, CH4 interferes with H2 measurement (e.g. Steel Top-Gas) All measuring values connected by common controller (via ext. signals possible)
Swap and change modules / controllers Multiple applications, multiple analyzers in one plant (e.g. Cement, Petrochem) Controller fails on critical application Swap out non-critical analyzer and replace module
Add additional measuring component(s) – (e.g. CEMS, new regulations) Purchase module only and add to existing system
19” rack to Wall Mount housing conversion Purchase new housing, move internal components
Modular System
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EasyLine So smart, they’re simple
ABB’s entrance into gasanalysis
Proven and reliablemeasurement technologyas in Advance Optima
Two different housingversions with a protectionup to IP65 (NEMA 4 eq.)
Intuitive and easy operation
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Key benefits EasyLine Easy solution for many applications
Excellent price-performance ratio
Measures up to 5 components in one unit
Combines up to 2 sensors in one enclosure
Top-gas (CO, CO2, CH4, H2)
CEMS (CO, NOx, SO2, CO2, O2)
Uras26
Uras26
Uras26
Electrochemical O2 Sensor
Magnos206 Magnos206
Limas23
Limas23
Electrochemical O2 Sensor
Caldos27
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Calibration CellsAvailable for all ABB photometers (NDIR, UV, FTIR)
Patented glass to metal welding technique
Filled with real test gas then sealed
20 years experience in production
Applied more than 25,000 times
Stability confirmed by independent testing laboratory
More than 10 years test period:
CO, CO2, NO, SO2 drift < 0.5 % per year
300
350
400
450
500
1990 1992 1994 1996 1998 2000
CO [ppm]
Analyzer1 Analyzer2
Drift: < 0.3 % / a
Components / Min. Ranges
Components EL3000 AO2000
Standard Optional Standard Optional
CO 0-100ppm 0-10ppm 0-50ppm 0-10ppm
NO 0-150ppm 0-50ppm 0-75ppm 0-25ppm
NO2 0-100ppm 0-50ppm 0-100ppm 0-50ppm
SO2 0-100ppm 0-50ppm 0-100ppm 0-25ppm
CO2 0-100ppm 0-5ppm 0-50ppm 0-5ppm
CH4 0-100ppm 0-20ppm 0-100ppm 0-20ppm
N2O 0-100ppm 0-10ppm 0-50ppm 0-10ppm
O2 0-2vol% - 0-0.5vol% -
H2 (dependent on gas composition) 0-10vol% - 0-3vol% 0-0.3vol%
Guide only – dependent on gas composition
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© ABB Group August 16, 2012 | Slide 14
LS4000Tunable diode laser analyzer
LS4000 – Laser Gas AnalyzerProduct overview
Analog outputs Digital outputs
Analog inputs (optional)Service Port (Ethernet)
Power supply
Receiver unitTransmitter unit
Junction box
Process purging is applied to keep the
optical windows clean.
The influence of temperature and
pressure variations is eliminated by
automatic dynamic correction.
In-situ, non-contact measurement with fast
response (~2 sec)
Suitable for temp. < 2732oF and pressures
up to 290 psi
Compact & flameproof (Ex-d)
housing approved for Class1 Div1
hazardous areas. Purging flange
Measurement of O2 (Vol%)
Interior design with minimal air space –no N2 purging for most applications
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ACF50004th generation FTIR based CEMS
ACF50004th generation FTIR based CEMS
1993
Cemas-FTIR
1996Advance
Cemas-FTIR
2002
ACF-NT
2013
ACF5000
More than 1,500 installations worldwide! 12/12/2014 | Slide 17
Test gas
CompressedAir
Gas Outlet
Sample Gas
FTIR
FID
O2
ASP - Block
MRCell
AirCleaner
Emergency purgeTest gas
Test gas
Burner Gas
ExhaustAnalyzer≥ 356°F
Sample Conditioning≥ 356°F
Sample Line ≥ 356°F
Sampling≥ 356°F
Stack
ACF5000Close-coupled design ensures no cold spots
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Electronic Box - Amplifier- Solenoid valvesRemote Service Unit
Gas Cell Box- Sample cell- Gas feeding - Fidas24 and ZrO2 Sensor
Interferometer Box
Electronic Box - FTIR
Air Cleaner Box
I/O Interface
Power Distribution
Instrument Air Distribution
Systemcontroller
Pre-engineered systemAll analyzers manufactured by ABB
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ABB Bomem FTIR Spectrometer
FTIR technology Drift free, virtually no recalibration
High resolution spectrometer (1cm-1) Lower detection limit and cross interference
Thermo-electrically (TE) cooled detector (DTGS) Improved sensitivity
Split architecture (gas path separated from electronics & optics) Better internal components protection Non-hygroscopic ZnSe beam splitter – insensitive to humidity
Long life optical components Solid state laser (20 years lifetime) IR light source (5-10 years lifetime)
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ACF5000Optional Validation Unit
Films and gas cells for all FTIR components as a surrogate for test gas
Allows on-going system validations
Can be triggered manually or automatically
Benefits No specialist required to validate measurement
Useful maintenance tool for plant technicians
Very quick and requires no cylinder gases
Future proof technology
Measure up to 15 measuring components
Add measuring components w/o additional hardware
Integrated FID and Zirconia O2 sensor
Formaldehyde measurement option
THC measurement using FTIR (equivalent to FID)
ACF5000Measuring components and ranges
*) Other ranges on request
ACF5000Measuring Ranges *
Component Method Min. Max.
CO FTIR 60ppm 3200ppm
CO2 FTIR 30vol%
NO FTIR 150ppm 1500ppm
NO2 FTIR 40ppm 300ppm
NH3 FTIR 6ppm 300ppm
N2O FTIR 25ppm 500ppm
SO2 FTIR 25ppm 500ppm
H2O FTIR 40vol%
HCl FTIR 10ppm 125ppm
HF FTIR 3ppm 10ppm
CH4 FTIR 10ppm 300ppm
CH2O FTIR 15ppm
THC FTIR 7.5ppm 150ppm
THC FID 7.5ppm 150ppm
O2 ZrO2 25vol%
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FTIR CEMS
Participated in trial at Holcim, Ste Genevieve in 2012
A number of issues experienced:
1. Test gas tag values not representative of actual HCl concentration
2. Cold spots at ‘spool piece’ between probe tube and probe filter
3. Spectral interference, resulting in positive offset to HCl
Subsequent visit to site resolved issues 2 and 3 above
Findings and improvements not published in official report
Separate addendum was published by ABB in Dec. 2012
ABB FTIR proven capable of meeting draft Performance Specs.
Returning to same site with new system for repeat trial (Jan 2015)
Practical Experience
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HCl losses around Sample Probe
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Trend HCl ABB and Company X
HCl_Company X
HCl_ABB
Com
pany
X
Corrective Actions
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• Special adaptor piece between probe tube and filter housing
• Insulated the flange• Increased probe temp. to 390degF
Note:Permanent installation likely to have suitable flange available.
Spectral Interference
Analysis found Formaldehyde present (0-5ppm)
Resulted in spectral residuals in region HCl measured
Corrective Action
Method for Formaldehyde measurement implemented 0.4ppm offset remained
Data reprocessed using new method for HCl Further improvement – interference at acceptable level
Retrofit solution available for current model
Improved method implemented in 4th generation FTIR system
0.8ppm offset to HCl
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Results after Corrective ActionsVery good agreement at upper and lower levels
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Los Gatos Research (LGR)Off-Axis ICOS technology
Founded in 1994, acquired by ABB in October 2013 Located in Silicon Valley (Mountain View, California)
46 Employees (Up from 32 in 2013)- 14 Ph.D. scientists
Adds innovative gas analytical measurement and enhanced laser capabilities to expand ABB’s measurement products in oil and gas, electric power and other industrial sectors
Unique laser absorption technology called Off-Axis Integrated Cavity Output Spectroscopy (OA-ICOS)
First developed Cavity Ring Down Spectroscopy (CRDS) in 1988 by Anthony O’Keefe (founder of LGR)
4th generation delivers superior performance, and is orders-of-magnitude less sensitive to internal alignment of components and to variations in local temperature and pressure
Los Gatos ResearchOff-Axis ICOS technology
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Conventional TDLASOverview
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• TDLAS: direct measurement of concentration with minimal calibration• Provides fast gas-specific measurements with no consumables• Ideal for monitoring in hostile conditions• Industry recognizes TDLAS for O2, NH3, HCl, CH4, H2S• ‘Single pass’ conventional TDLAS may not provide sufficient sensitivity
Beer-Lambert Law: I/Io = 1-exp(Leff)I/Io = change in laser intensity() = absorption coefficientLeff = effective optical path length
Limitations of various types of Conventional TDLASLimited to gas matrices with little or no background absorption
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Limited sensitivity due to: Significant signal/noise issues Resistant light source/laser noise (RIN) Short path lengths
Nonlinear at high concentrations (ppm - %v) Cross interferences and false positives Limited dynamic range Optical bench & TX/RX alignment issues
Manufacturing complexity OPGD configuration concern
Sensitive to vibration and obscuration Internal component reliability External “air blower” mechanisms
Optical cavity provides longest effective path length of any laser analyzer available (up to 15 miles or longer)
Very robust – exact optical bench alignments are not critical
Mirrors cleaned in the field in <20 minutes! OA-ICOS can be employed at any
wavelength from UV to mid-IR LDL’s generally @ 1-50 ppb in complex
matrices and as low as 200ppt range for some gases in ambient air
Single and Dual lasers in single cavity for multi-species detection
Setup for LGR’s patentedOff-Axis ICOS technique
LGR’s solution: Off-Axis ICOSCombines high resolution absorption with long path lengths
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Cavity Enhanced Absorption Spectroscopy (CEAS)Measures high-resolution spectra, yields accurate data
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Measures baseline, absorption, detector offset and Ring down time in every scan to confirm path length at every data point!
Scan laser at 100-1000 Hz, measurements every 1-10 ms.Averaging ~ 1 sec of data (typical)
Cavity pressure at 1/10 to 1/15 of 1.0 Atmosphere
Operating at lowerthan ambient pressure narrows spectral peaks and improves Voigt Profile for “fit”
“Chemometrics fit” mode enables quantification of multiple gases in complex mixtures simultaneously with main component Voigt fit
Enables single-laser instrument to accurately report multiple gas species for best value proposition
Facilitates challenging process petrochem/chemical applications
CEAS: Unique ability for multiple integration capabilityHighly resolved Voigt fit integration plus Chemometrics fit
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LGR Analyzers for Industrial Applications: On-board Storage of Direct Spectra Provides Validation
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OA-ICOS is a first-principles direct measurement that “proves” the measurement using live and/or recorded spectra to“validate”analyzer response. Confirm and/or troubleshoot process and emissions events On board storage load is variable with data collection rates.
Experimental SetupSimple, robust, serviceable
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Off-Axis ICOSPackaging Options
Portable 19” Rack 19” RackExperimental setup Standard version Temp. stabilized version
Demonstrates how Sufficient for most Peltier cooler maintainsrobust the technology is applications unless trace constant temp. for optimum
ppb or high ambient temp. performance
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FAST Acetylene in Ethylene for effective Process Control strategies.
End Users need Class 1, Division 2.
LGR looking for Customer Partner Evaluation sites
Application is not Beta – only the enclosure
Expectation is OA-ICOS could perform with as much as an order of magnitude better sensitivity than any other option
Oil & Gas (Refining, Chem/Petrochem) Acetylene in Ethylene
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ICOS Faster than GC enabling active control of ethylene process
No mirror fouling or misalignment issues
OEM for Yokogawa since 2007
LGR advanced OA-ICOS as much as an order of magnitude more sensitive!
Acetylene + Methyl Acetylene in EthyleneAcetylene @ ~1000 ppm, Methyl Acetylene @ ~5000 ppm
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Multi-gas measurements simultaneously in complex flows LGR analyzer uses patented Off-Axis ICOS with chemometric data analysis Spectra provides stored verification of observed events and phenomena
Trace Ammonia in Ethylene
Laboratory feasibility studies show performance for diluted sample calculated to produce signal @ 0.725 ppm
Expectations for process stream performance at 2-5 x better sensitivity with attention to flow control and stable sample conditions
720-730 ppb NH3 in 78% Ethylene, 22% Nitrogen
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Performance of OA-ICOS; H2S, NH3 with H2O & CO2
Detection of H2S + NH3 with CO2 and H20 – ONE laser H2S = 702.1 ppb, NH3 = 12.64 ppb
ONE laser - multiple gases
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Applications include: HCl, NH3, CH4, CO, CO2, O2
System configured with or without Dilution, and for Pre-or Post scrubber operations
CEMS Installations; CO, CO2, O2, H2OHCl, HF and NH3 for unique requirements
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OA-ICOS for HCl CEMS
Combination of HCl and H2O gives added confidence in HCl measurement – usually clear if H2O values are feasible
Possible to combine HCl, NH3 and H2O in one analyzer
Compatible with dilution systems up to 150:1
Also suitable for retrofit to Mercury CEMS
Visualization of spectra very powerful diagnostic tool
Optical cavity can be serviced on-site with minimal training, ensuring maximum availability
LGR HCl/H2O analyzer has been successfully tested on two different U.S. coal-fired power plants- Combined with Mercury CEMS (35:1)- Combined with dilution-extractive CEMS (100:1)- Further trials planned – 150:1, 400-500ft sample line
Excellent solution for MATS compliance
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Performance of OA-ICOS; Extractive Ammonia
Recovery from 0.1819 ppm NH3 to 0 Air = 13.7 seconds External pump w/ Flow Rate = 1.5 liters/min “Moist” sample & Wetted surfaces reduce memory Dilution reduces extent of memory retention High Performance NH3 MDL of 0.60 ppb
Stack Gas 100X Dilution, measuring 181.9 ppb
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Performance of OA-ICOS; HF
HF+HCl Dual Laser and Portable configurations available NH3, CO2, CO, O2, H2O SO2 also.
Ambient Air Leak Detection, 0.20 ppb
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LGR OA-ICOS Laser Analyzers: Value Proposition
OA-ICOS provides most reliable, accurate & precise spectra and integration data -both retained in the analyzer
Zero & Span Calibration not required. Bump Test Verification check performed at the Analyzer in the Shelter
No alignment of any kind is ever required, no dust/obscuration concerns
Dilution & highest dynamic range affords wide range of stream composition tolerance
Reliable, Accurate, Easy and Economical COO
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Proposed PM Schedule:
Calibration: Not Required
Verification: Monthly is recommended
Clean Mirrors
1X Annually (20 min.)
Replace Flow Pump Diaphragm
1X per 5 years (30 min)
Thank you…
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