GEAI Process TOC Applications Solutions-external · 1 hr for manual cleaning ... • In addition to the sour water stripper process, ... GEAI Process TOC Applications_Solutions-external.pptx

GE Analytical Instruments (GEAI) Process TOC Applications

Sievers InnovOx TOC Analyzers 2

@ 2013, GE Analytical Instruments

• Process TOC Product Introduction• Industry and Application Overview• Key Applications• Case Studies

Agenda

Process TOC Product Introduction



Brief History of TOC for Industrial Apps

• Strong value proposition / ROI for process control, leak detection, WW system optimization.

• Early “industrial” online TOC instruments were lab instruments extended into online applications with little understanding of the challenging sample matrices and punishing physical environments.

• Most early attempts to extract value from online TOC monitoring failed due to under-designed instrumentation, poor uptime, high COO.

• Today’s instruments are designed specifically for the harsh sample and environmental conditions experienced in HPI/CPI applications.

• Industrial components, electronics, machined parts• Robust sample handling• NEMA 4x; IP-56; Class I / Div II; ATEX; RMD (Remote Monitoring and Diagnosis)• Analytical techniques designed for high salts and particulates

Sievers InnovOx TOC Analyzers 10/16/2013

5

Sievers InnovOx Super Critical Water Oxidation

InnovOx SCWO Reactor

Sample matrices:

• Brine

• Cellulose

• Humic Acid

• Particulates



GE’s Sievers TOC Analyzer & Sensors Line



Process TOC Analyzer Technology Comparison

SCWO (GE) Two-Stage Advanced Oxidation (Ozonation)

Combustion UV/Persulfate

Brine and salt Handle solution with up to 30% chloride and 12 % calcium

Leads to analyzer failure due to collection of un-oxidized particulates in the furnace

Reduces persulfateoxidation potential with concentration as low as 0.05%

Auto Self Cleaning Auto self cleaning Not available, typically requires analyzer to be offline for 1 hr for manual cleaning

Calibration Stability Allows a 12-month calibration interval

Allows a 6-month calibration interval

Requires calibration every 2-3 days due to furnace buildup and IR bench contamination

Requires calibration every 2-3 days due to UV light source scaling that causes incomplete oxidation and drift

Gas Needed Clean tank/house air Zero grade air + oxygen Zero grade air + oxygen Nitrogen, zero grade air

Reagent Needed Flexible supplier Sole source supplier for catalyst Flexible supplier Flexible supplier

Capital Cost Medium High Low to High, varies by vendors

Low to Medium

Process TOC Industries & Applications



Sievers InnovOx TOC Analyzer: Industries

Hydrocarbon Processing

Microelectronics

Food & Beverage

PharmaceuticalMunicipal Water and Wastewater

Chemical Processing



Process TOC Application Overview

Wastewater process optimization• Nutrient loading• MBR optimization• Prevent exceeding discharge limits• COD/BOD correlation – continuous,

real-time monitoring.

Heat exchanger leak detection

Detect product contamination in steam feed and condensate

Cooling water contamination

Production process control

Surface / storm water runoff



MAKE-UP WATER WATER REUSE

WASTEWATERChallenges: varying levels and types of organics, varying TSS• Wastewater chemicals• UF/MBR• ZLD-thermal• TOC analyzers

PROCESSChallenges: maintain production for full run length• Antifoulants• Corrosion inhibitors• Antifoams• Demulsifiers• Oxygen scavengers• TOC analyzers

FEEDSTOCK

PRODUCTS

SOURCE WATERChallenges: amount/scarcity, quality (TSS, TDS, organics)• UF/RO filtration• Clarification chemicals• Mobile/Water Outsourcing (BOO)• TOC analyzers

UTILITIESChallenges: system stress from pushed operations• Cooling chemicals• Boiler chemicals• TrueSense* monitoring and control• TOC analyzers

Process TOC Application Overview



Wastewater Influent

• TOC application locations:

After API separator or before EQ tank (Front-end)

Prior to bioreactor (Pre-biological)

• Objective: recognize if organic overload/upset in the influent to WWTP

The capacities of the bioreactor or EQ tank are designed based on organic load in wastewater.



TOC-COD Correlation

COD

(ppm

)

TOC (ppm)

Wastewater Effluent

• BOD or COD is time consuming analysis and does not provide continuous analysis like TOC

• The WWTP operators typically need real-time data for process optimization, and to retain, divert, or dilute discharges prior to causing damage

• Correlating TOC to BOD/COD allows a facility to better manage their WWTP and avoid paying high organic load surcharges or penalties



Potential TOC Locations for Reuse or Direct Discharge

MBR Simplified Treatment Process

Tertiary Filtration Process

Wastewater

High Quality Effluent for

RO Feed

TOC

TOC

TOC

TOC

TOC Applications

1. Monitor if organic overload/upset in the influent to bioreactor

2. Monitor upstream treatment efficiency, protect RO and insure discharge or reuse quality

1

1

2

2



Desalter NESHAP Stripper API

Dissolved Gas

Flotation

3o

Treatment or Reuse

Discharge

Sludge Handling

DGF Skim

SlopTanks

ski

mski

mwat er wat er

solid s

solid s

solid s

Centrifuge, Press

Solids To Sludge

Handling

Process Units

oil

Product

solids

Cla

rifie

r(s)

Aer

atio

n A

erat

ion

Tank

(s)

oil

Sour Stripped

Water

Potential TOC Locations for Refinery WW Treatment



Leak Detection

• TOC can demonstrate the ability to accurately measure an upset and resume running condensate or detect any leads in heat exchangers for cooling water.

• TOC can help companies decide whether additional treatment is needed for stormwater or if there is any contamination in the stormwater



Chemical Dosing Optimization

• Removal of metals such as selenium in sour stripped water requires the addition of a chemical oxidant (e.g. hydrogen peroxide) prior to coagulation/settling. In this application, background organic carbon is an oxidant scavenger that greatly reduces the efficiency of the treatment process. Amines or other organic carbon reacts with the oxidant before the target compounds (e.g. selenium).

• An InnovOx TOC Analyzer helps optimize the oxidant dose for the treatment process, thereby greatly increasing the efficiency of the process. In some cases, companies can reduce the oxidant dosage and therefore reduce cost. The cost of oxidant exceeds $100,000 per year at some facilities.

• In addition to the sour water stripper process, optimizing chemical dosing in the tertiary wastewater treatment process (chemical oxidation polishing step) using TOC is possible.

Case Studies



WW Influent Monitoring

Customer Summary

Industry Segment: Food & BeverageMain Product: Beer, Misc. Beverages Applications: WW Influent

WW Process Optimization

Case Details

Two WW treatment plants are located at the customer site. One is for process WW, and the other one is for general WW and domestic WW from the city.

InnovOx On-Line TOC analyzers are installed at each influent monitoring point, prior to the activated sludge biological treatments. The monitoring data help to understand any organic loading spikes from upstream, and make necessary adjustment of oxygen, ammonia dosed to the system operations.

400-600 ppm TC in influent of general WW, 900-1,000 ppm TC in influent of process WW



WW Process Control & Effluent COD Correlation

Customer Summary

Industry Segment: Food & Beverage Bottling PlantMain Product: Soft DrinksApplications: 1. Control nutrient dosing

2. Correlation to COD (Effluent)

Case Details

Monitor influent to WW plant (GE ZeeweedMBR). Based on TOC value, customer controls ammonia dosed into equalization (EQ) tank. EQ tank is undersized, has to turn it over 3-5 times per day, critical to understand organic loading. Typically run 1200 ppm, but can spike above 3000 ppm (alarm at 3000 ppm).

COD samples run 6 times per day. COD:TOC correlation study is done with a result of COD:TOC at 3:1 ratio. Customer uses TOC results to monitor effluent quality.



WW Bioreactor Optimization

Customer Summary

Industry Segment: Food & BeverageProduct: Beer, Misc. BeveragesApplication: WW Process Monitoring

Case Details

Control algorithms around TOC to ensure stable bioreactor operation

TOC detects increases on reactor effluent, recommend decrease reactor flow rate to prevent biomass overflow & maintain solid retention time.

• Helps retain biomass• Improve biogas production• Improve organic removal• Reduce chemical usage by using the control actions

of EQ tank level, recycle ratio, reactor flow, and pH control.



Steam Condensate Spill Detection

Customer Summary

Industry Segment: Hydrocarbon ProcessingApplication: Spill Detection

Case Details

Steam condensate is used for boiler feed water in the process. Any hydrocarbon leak from heat exchanger to condensate damages the boiler integrity and brings downtime to the process.

The customer smelled/observed the oil sheen in the condensate, however, is not able to estimate the time of release and quantify the organic loading. Without the data, it is very challenging to design a treatment system to protect the boiler.

InnovOx On-Line TOC Analyzer provided to the customer as an onsite demo gives the baseline TOC reading of ~2 ppm, several spikes of TOC up to 20-40 ppm observed during the first two weeks after installation.



Cooling Water TOC Monitoring

Customer Summary

Industry Segment: Cogen PlantApplication: Spill Detection

Case Details

Problem: the most common environmental problem associated with cooling water is the leakage of hydrocarbons into the cooling water from aging heat exchangers, which subsequently causes high BOD/COD levels in the blowdown. Due to increasing environmental concerns and the impacts of the inherent cooling tower problems, some state (TX) permits require monitoring the cooling water system for benzene and TOC in the return cooling water.

Solution: as a good engineering practice, and to ensure that the hydrocarbon leakage can be detected early, a plant installs an online TOC analyzer in the common cooling-water return header and provide sample connections at different return subheadersfor easy leak identification.



For more information

Industry Application Notes/Case Studies:www.geinstruments.com/Library

Product information: www.geinstruments.com/InnovOx

Quote Request or Questions:www.geinstruments.com/Forms/Request-More-Information.aspx

Documents

GEAI Process TOC Applications Solutions-external · 1 hr for manual cleaning ... • In addition to the sour water stripper process, ... GEAI Process TOC Applications_Solutions-external.pptx