Applied Controls Analytical System Integration

2014 National Sales Meeting

CGA: Continuous Gas Analyzers Analyzer or Application – The Question

Bruce Herman - ABB Process Analytics

© Copyright 2014 ABB

All rights reserved

“The information contained in this document is to be used only for the purpose intended. Any unauthorized use, reproduction, distribution or disclosure to third parties without

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ANALYZERS and APPLICATIONS 

• name where ABB sells CGA analyzers

• identify measuring points in the major applications

• select the right analyzer modules for applications

Agenda - Focus Points • CGA• The Frankfurt Connection

PRESENTATION FOCUS

• Product overview• CGA: AO2000

CGA –the product

• Where do you find CGA • Emissions • Process

APPLICATIONS

• POI• (Points of Interest) DIALOG

Advance Optima –• Available for >15 years• Powerful controller logic • Class 1, Groups A,B,C,D,

Div 2 • Engineered

ADVANCE OPTIMA 2000

Reliable – Economic – Powerful

Continuous Gas Analyzers

COCO2

NOxO2

Sample Handling

The Benefits of an Integrated Analyzer Concept

The most important area of applications for continuous gas analysis. Combustion processes can be found in many different industrial areas,

COMBUSTION PROCESSES • the generation of heat

• and electricity,

• Process steam production,

• Municipal and hazardous waste incineration,

• Surface treatment for example in annealing processes,

• Melting processes as used in metal or glass production,

• Roasting process for example iron ore roasting, sintering,

• Steel production and

• Cement production, … to name only the most important.

• CO2, H2O, N2 expected

• CO, HC, excess O2 incomplete combusion

• SO2, NOx Sulfur in fuel, N2

• HCl, HF (Waste Incin)

• Hg, Particulates

Combustion efficiency Ideal combustion needs the right amount of oxygen.

The oxygen value can be measured with a paramagnetic oxygen analyzer

Efficiency of DeNOx process Nitrogen oxide and nitrogen dioxide are a major cause for environmental damage.

These components are removed by injection of ammonia.

The injection of ammonia is regulated via the NO/NO2 concentration in the exhaust gas. The efficiency of this process is controlled by monitoring the outlet for excess ammonia. Analyzers used are infrared photometer

Infrared for NO or alternatively ultra-violet photomete for NO and NO2, and laser

analyzer for NH3 measurement.

Electrostatic precipitator The typical measuring component is carbon monoxide.

Since CO is a flammable gas this measurement represents a safety measurement to avoid explosions.

Infrared photometer.

Efficiency of the DeSOx process (desulfurization) The efficiency of the flue gas desulfurization is monitored

by measurement of SO2 with Infrared.

Alternately UV

The analyzer modulesmodule name type typical

Uras 26 NDIR photometer CO, CO2

Limas11 IR IR photometer CO,CO2,

HCl

Limas11 UVLimas 23 UV

UV photometer NO, NOx

Magnos 206 Paramagnetic, dumbbell

O2

Magnos27 Heavy duty O2

Caldos 27 Fast silicon sensor, TC

H2

Caldos 25 Glass coated TC ChlorineNH3, SO2

FIDAS24 Flame ionization

Fidas24NMHC

Flame ionization Non-meth HC, VOC

ZO23 Zirconium dioxide O2 traces

LS4000 Laser in-situ O2, CO, NH3

Oxygen cell chemical O2

ADVANCE OPTIMA 2000

ABB

Analyzer Modules

Infrared Analyzer Module ABB Uras 26 CO

CO2SO2NOCH4….

Uras26Fulfils all the requirements for a lot of applications

High Stability of zero and span point<1% drift per week

High Sensitivityand smallest measuring ranges 0... 5 ppm CO2

High Selectivitysmallest cross sensitivities optimized for the main applications

Smallest detection limits< 20 ppb in a range of 0…5 ppm CO2

Suppressed range like 98…100 Vol% N2O

High repeatability< 0,5% of the range

Gas filled detector

Membrane condensator

Sample cell

N2

CO SO2

NO CH4

N2

N2

N2

N2

NO

CH4

N2

N2

N2

CO

SO2

p

Infrared, Principle

ABB Uras 14with 4 measured componentsand calibration cells

Analyzer Modules

Photometer Analyzer Modules ABB Limas 11-UV/IRABB Limas 23 UV NO

SO2NO2

NOx = NO + NO2

Limas 11-UV Various Measuring components: NO, NO2, SO2, H2S, CS2, COS, Cl2 and NH3

Low measuring ranges: 10 ppm NO,

High Selectivity by best choice of- Interference and Gas Filter- Internal cross-sensitivity correction

High Stability due to electrodeless source & unique 4-Beam Method

Compact & economical solution for flammable, corrosive & toxic process gases

Calibration without test gas bottles

Simple adaption to the measuring task

Limas 11 - Schematic DrawingM

M M

Source FW1

FW2

CU

D2

D1

MC

CL1CL2

CL3

BS

IR - Source M MotorFW1 Filter wheel 1FW2 Filter wheel 2

BS Beam splitterMC Measuring cuvetteCL1,2,3 Collimator lensesD1,2 Detectors

CU Calibration unitIF Interference filtersGF Gas filters

IF

GF

GF

IM1

IR1

IM2

t

IR2

t

Analyzer Modules

Oxygen Analyzer ModulesMagnos 206/27

Magnos – and Oxygen Technology

•Magnos206•Measurement in many applications•Very few interferences •Paramagnetic analyzer•Measuring with a dumbbell

•Magnos27• Preferred for rugged

applications• No moving parts • Paramagnetic analyzer • Measuring using thermal

character

•Electrochemical • Simple and economical

•Laser Diode • In Situ • NOT Paramagnetic

Magnos 206Fast, Reliable MeasurementMagneto-Mechanical Principle

Magnos27 Technology

N

S

N

S

Paramagnetism of oxygen

Two chamber system (measurement and reference)

Measurement chamber is located in a magnetic field

Temperature dependent resistors

Measurement effect: Increased circulatory flow proportional to oxygen concentration measured through thermal conductivity.

N

S

Temperature dependentresistors

( Pt/Glass ... ca. 180 °C )

Bypass

60 °C

Magnos 27Robust Measuring Cell Thermomagnetic Principle

Oxygen SensorExtended Range of Application,Suited for Stack Gas Monitoring

PTFE Membrane

Cathode ( Au )

Anode ( Pb )

-

+

Sample gas

Electrolyte ( acidic )

LS4000 (TDL) Overview

In situ tunable diode laser analyzer

Measurement of oxygen (from 0-1 to 0-100Vol%)

Stand-alone operation

Compact & flameproof housing approved for use in hazardous areas (ATEX/IECEx/FM/CSA) (Class I, Div 1)

Dynamic correction of changing process conditions

LS4000Product overview

Caldos 25Highly corrosion resistantglass coated resistors

Caldos 25Independent of Ambient PressureSophisticated Measuring Cell

Reference side Measuring side

Bypass

Glass-coated

Glass

60 °C

Caldos 17Fast Measurement

Analyzer Modules

FID Analyzer ModuleFIDAS24

Fidas24Key Features at a Glance

New FID analyzer for Advance Optima and EasyLine series

Continuous hydrocarbon and non-methane hydrocarbon analysis

Large operating range: from low ppm to high vol%

Easy to operate

AO2000 Series Analyzers

AO2000 Series Analyzers

AO2000 Series Analyzers

APPLICATIONS • Power Generation • CEMENT KILNS • boilers• furnaces • heaters• incinerators • (if it burns…. )

CEMS – 70%

• Cement Kilns • CO2 in hydrocarbons• CO in hydrogen• H2 in Cl2 • H2 in Hydrocarbons (nitrogen header..) • O2 deficiency • FID, incinerators, Hydrocarbon in water

PROCESS – 30%

• NO and NO2 measurements for CEMS (LIMAS23 and LIMAS11) • Landfill gas measurements

• CH4, CO2, O2 • GREENHOUSE GAS• CSA has a regulation

• Nitric Acid Plants • NO/NO2 ratio issues • Partner Partnering

Special Emphasis

Integrated Remote Control Full Access to Gas Analyzers Functionality

Thank You For Your Time

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