LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG
Ceramic Gas Sensors for Optimisation of Combustion
Processes
Dr.-Ing Frank Hammer
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG
Outline
› Overview of LAMTEC
› Sensor Technology
› Manufacturing Technology
› Combustion Optimisation
› Application
› Summary
› References
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG
Overview of LAMTEC - Company Profile
› LAMTEC Sensors and Systems for Combustion Engineering (LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG) Wiesenstraße 6, 69190 Walldorf, Germany
› Established: 1st Juli 1995 as MBO from ABB
› Shareholders: Dipl.-Ing. Hans-Jürgen Altendorf, Dipl.-Ing. Bernd Jülg, Dipl.-Ing. Harald Weber, Olaf Winne
› Subsidaries/ Associated Companies: • LAMTEC-Leipzig GmbH & Co. KG, Germany (100%)• LAMTEC EA Buchon EA Buchon South Korea (80%) Jan. 2006• LAMTEC Poland• LAMTEC SEA Ltd. Kuching Malaysia (2010)• OOO LAMTEC Moscow (2012),• Escube GmbH & Co. KG Stuttgart, Germany (100%)
› Employees: 100 (2 trainees)
› Turnover 2013: 14.3 Mio. €
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG
Overview of LAMTEC - Locations
Headquarter Walldorf LAMTEC EAST ASIA Ltd.Buchon, South Korea
LAMTEC LeipzigDevelopment of hard- and softwareManufacture of flame scanners
LAMTEC Neu AnspachDevelopment of electronics
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG
Overview of LAMTEC - Products/Applications
LAMTECProducts/Applications
Customers
Electronic burnercontrol system
Fuel-/air ratio control
IR/UV
Flame monitoring system
Process and fault indicator system
O2 measurement devices
Option:Detection of non-burned CO/H2
Boiler manufacturerPlant manufacturerMeasurement device manufacturer
Burner manufacturer Industry
Applications:Power plant/waste combustionChemical industryIndustrial applicationMeasuring- and control technologyResearch facilities and development
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG
Overview of LAMTEC - Sales Partner
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG
Overview of LAMTEC - Product Range
Burner Control
Electronic Fuel-/Air Ratio Control
Volume Flow Measurement
Flame Detection
O2 Optimization
O2 Measurement
CO/O2 Monitoring
Process and Fault Indicator System
Product Range
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG
Sensor Technology – Non-Nernst Principle
Design of a CO measurement cell
Non-Nernst Sensor Voltage
cathode
Ad. phase:
Gas phase: pO2=21%, pCO=1%, (Rest N2)
O2,ad= 99%, COad= 1%O2,ad= 90%, COad= 10%
US
Solid Electrolysis
Aad
Kad
CO
CO
S C
C
F
TU
,
,
ln2
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG
Sensor Technology – The Sensor Voltage
› Langmuir adsorption isotherm• monomolecular adsorption layer• ads./des. in stationary state condition (SS)
› US is a function the coverage of anode and cathode A, K
• KA=KK :identical reaction kinetics SS-constants through identical reactions (TE=TK=TS,
one measurement element)
• Dg ad,A Dg ad,K :Comparison of Gibbs enthalpies through similar adsorbents/adsorbate binding
strength (identical basic materials of electrodes on three
phase boundary, alloy of two phase layer for modification of adsorption on the
anode)
AK
AKKadAad
K
AS
S
S
T
gg
F
TU
)1(
)1(lnln
2,,
S
ad
ad
T
g
CO eK
c (
1
1
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG
Sensor Technology – The CO Sensor
Characteristics of Sensor
› planar
› multi-layer
› miniaturised
Functions of Sensor
› Solid electrolyte
› Non-Nernst principle
› electrocatalytic electrode
Carrier substrate
3,5
20
t=0,6
Contact point
Zirkonia
Heating coil
Glass cover
Electrode 1 Electrode 2
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG
Manufacturing Technology – Thick Film Technology
Screen process engineering:
› flexible
› cost-efficient
› reproducible
› mass producible
squegee
Screenjump
screentension
screensquegee
angle
pressedthick film
screen printing pastecarrier substrate
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG
Manufacturing Technology – Raw Materials
Sensor materials
› Al2O3-carrier substrate
› YSZ-functional ceramics
› Pt-heating coil
› Pt cathode/Pt-alloy anode
› Special glass cover
Innovative aspects
› laser technology
› hybrid layer technology
› sub- and nano-powder
› ceramic printing pastes
SolutionII
Solution III
Solution IV
printing
Medium
Solution V
paste
HOdestilled
2
Solution I
stir 400 U/min25 °C
400 U/min60 °C, 5 min
400 U/min25 °C, 2 min
400 U/min25 °C, 2 min
400 U/min25 °C, 2 min
400 U/min25 °C, 2 min
Cool down
500 U/min65 °C, 45 min
100 Umin25 °C, 60 min
Solution V
Binder I
Plasti-cisers
Dispergingagents
Binder II
Defoamer
Ceramicpowder
Moisturi-zers
screen
printingScreen
stir
stir
stir
stir
stir
stir
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG
Manufacturing Technology – Process Optimisation
Simplification of the production steps through
› Co-firing which is used in the multi-layer process of the manufactured sensors
A decrease in
› Production steps
› Production time
› Tempering processes
› Sintering time
› Energy costs
› Manufacturing costs
Production chains with integrated process controls
co-firing
Printing Electrode 1
Drying
Printing Electrode 2Check/Testing
Drying
Printing heating oil
Drying
Printing YSZ-Ceramic
Presintering
Paste preparation
VentilationPortioningPositioning
Screen /SMD moulding
Cleaning of substancesMechanismPositioning
Carrier substrate
Cleaning of substancesDegreasingPositioning
Activation Electrode 2Preliminary testHard machining
Final testing
Check/Testing
Check/Testing
Check/Testing
Check/Testing
Check/Testing
Check/Testing
Check/Testing
Check/Testing
Check/Testing
Check/Testing Check/Testing Check/Testing
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG
Manufacturing Technology – Sensor Optimisation
Thermal analysis
› instationary heating performance
› stationary temperature distribution
› stationary voltage distribution
optimal sensor geometry
Thermography measurement
› comparison between theory and practice
› calculation of the sensor temperature TS from the electrical operating data Rh
optimal operating temperature
500
600
700
800
900
13 15 17 19 21 23 25
y = 0.7673x2 +17.139x+ 76.959 R2 = 0.997
c)
Heating resistor Rn in Ω
Sen
sor
tem
pera
ture
Ts
in K
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG
Application – The Sensor System
Sensors / Housing
› small (< 3W)
› robust (> 3 Jahre)
› temperature stability (< 200°C / 500°C)
› cost efficient (< 15€)
› fast (< 1s)
Elektronics (exaple)
› supply unit 14-20 V
› temperature control
› signal processing
› analogue outputs 0-10 V or 0/4-20mA
› relay outputs
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG
Application: Combustion Technology
Today: Combustion Systems
› Fossil fuels• Limited resources
(coal, gas, oil)
› Pollutant emission • CO, NOx, CO2 etc.
› Danger: Global warming
Monitoring and Control of
Combustion Systems
Tommorow: Fuel Cells
› Chemical reacting agents• Unlimited resources
(H2+ atmospheric oxygen)
› Pollutant emission • No
› Potential for damage: H2
Safety Monitoring of
fuel cells and hydrogen
infrastructure
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG
Application – Combustion Characteristic
Pollutant makers
› Traffic
› Industry
› Household and small-sized burners
Existing sensor systems
› Automobile: probe
› Industry: / flue-gas probe
› Small-sized burners: not available!
Þ Development of miniaturised CO-Sensors for combustion optimisation
CO
CHnmRuß
0.1 0.2 0.4 0.6 0.8 1 2 4 6 8
1,911,301.031.005
Incomplete combustion
Flue gas heat loss
Ruß
, CO
, CH
nm
effi
cie
ncy
Em
issi
on
edg
e
Com
bust
ion
fuel
s
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG
Application – Combustion Regulation
Combustion Control increases
› The operational range
› reliability of operation
› safety
Combustion Optimisation
› increases the efficiency
› lowers fuel consumption
› Minimises pollution
S2
S1Processo r
AirFuel
BurnerFlue gas channel
Exhaust air
ProbeElectronic control
Combustion chamber
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG
Sensor element Status: series
Function tested in oil, gas and solid fuel firings since 1999
Production more than 20.000 pieces since 2002
Reproducibility Heater side Sensor side
9±1, requirements are fulfilledrequirements are fulfilled for combustion optimisation
Field tests no blackouts of the sensor element since March 2002
Life time tests tests in oil and gas since Mai 2003, two peripheral blackouts, tests go on
Price now: 250€ per piece; goal: 5-10€ per 100.000 piece
Summary – State of the Art
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG
Housing: Status: „series“
Function around 2000 housings in operation (three different types)
Production Integration standard high temp.
experiences with series:without problems up to 200°C, condensing atmospheresup to 450°C, condensing atmospheres
Life time tests tests in gas and oil since Mai 2003, two blackouts, problems solved, tests go on
Price now: 250€ per piece; goal 3-6€ per 100.000 pieces
Summary – State of the Art
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG
Electronics Status: series
Function around 1000 units in operation since Mai 2003
Development Feb. 2003: prototypeMai 2003: pre-seriesOct. 2003: redesign pre-seriesMarch 2004: zero series
Life time tests no blackout since Oct. 2003
Price 500 € per piece
Summary – State of the Art
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG
Summary – State of the Art
Field tests (excerpt)electronics
Status: „ pre-series with demonstrator
Burner Boiler Testing site Testing time
Oil, blue flame Buderus LAMTEC/Odenheim since Sept. 2002
Oil, blue flame Viessmann VITO/Belgium Jan.-Feb. 2002
Oil, blue flame Rotex HLK/Stuttgart Jan. 2003
Gas, atmospheric Senertec VITO/Belgium Jan.-Feb. 2002
Gas, atmospheric Klöckner LAMTEC/Walldorf since Dec.1999
Gas, condensing Bosch Junkers HLK/Stuttgart Feb. 2003
Gas, condensing Buderus LAMTEC/Reisen since Aug. 2002
Gas, condensing Buderus LAMTEC/Östringen March 2004
Bio mass Hoval CSEM/Switzerland Feb.-March 2001
Bio mass Brunner FH Karlsruhe/KarlsruheSept. 2003
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG
References – Long Term Measurement
Endurance test over 11 months
› identical characteristics
› no identifiable deterioration
› sensitivity increases slightly
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG
References – Sensors in Application (1)
Front view of a dual boiler 50-1.000kW
› 16 CarboSen1000 sensors were tested:• in condensing flue gas
Tmax = 80°C100% condensation !
• directly in the combustion chamberTmax = 600° !!No condensation !
Sturzbrenner
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG
References – Sensors in Application (3)
Mounting position in the condensing flue gas channel
› 4 CarboSen1000, plugged in
› 4 CarboSen1000, hanging
› 1 Lambda probe, plugged in
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG
References – Sensors in Application (4)
Mounting position in the hot incinerator
› 1 CarboSen1000 immersion probe
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG
CarboSen
27
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG
CarboSen
Miniaturised Sensor for Detection of Non-burned (CO/H2) in Combustion Exhaust Gas
28
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG
CarboSen
29
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG
Measurement Principal of CarboSen1.000
30
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG
CarboSen
Sensor Assembling
› 11 layers incl. carrier
› Measure: 20mm x 3,5mm x 0,7mm
› Material: ceramics, glas, platinum, gold• Thermally and chemical robust
› Production in thick and thin film process • Cost-effective, suitable for mass market
31
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG
CarboSen
Characteristic
0
20
40
60
80
100
120
140
3000 3010 3020 3030 3040 3050 3060 3070 3080 3090 3100
Zeit in s
Us
en
in m
V
0
50
100
150
200
250
300
350
400
450
500
CO
re
fere
nz
in p
pm
U Sen 01 in mVU Sen 02 in mVU Sen 03 in mVCO MRU in ppm
32
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG
Test Plant of Oil-Blue Burner
Qualification or reference measurement in pipe of oil-blue burner
4 CarboSen1.000 in flue gas pipe
Reference System (KS1D)
33
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG
CarboSen1.000ST
34
Characteristics:
› Measurement of COe directly in humid flue gas up to 150°C, also condensing› No reference air necessary› Protection class IP67
Applications:
› Natural gas, fuel oil EL
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG
CarboSen1.000
35
Characteristics:
› Measurement of COe directly in humid flue gas up to 400°C› Elektronic is integrated in sensor head› No reference air necessary› Protection class IP67
Applications:
› Natural gas, fuel oil EL, pellet, piece wood
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG
Thank you for your attention
Questions?
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG
Contact:
Steven Craig – President, Hays Cleveland
Phone: (216) 398-4414
Fax: (216) 398-8558
E-Mail: [email protected]