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In the hydrocarbon processing indus-try (HPI), cracking is the processwhereby complex organic molecules(e.g.heavy hydrocarbons) are brokendown into simpler molecules by thebreaking of carbon-carbon bonds inthe base material. The rate of crackingand the nature of end productsstrongly depend on the temperatureand presence of any catalysts. Processautomation equipment including gasanalysis instrumentation contributesessentially to control and optimizecracking processes.

Siemens Sensors and Communica-tion, a leader in process analytics, hasproven worldwide its competence toplan, engineer, manufacture, imple-ment and service analyzer systems foruse in cracking plants.

This case study provides detailedinformation about that.

Crude oil processingCrude oil is a complex mixtureof hydrocarbon compounds andrelatively small quantities of othermaterials such as oxygen, nitrogen,sulphur, salt and water as well asinorganics and metals. It occurs nat-urally in the ground and was formed

millions of years ago.Crude oil varies from source tosource in composition and colour.It is typically mixed with gases,which have to be separated fromthe crude oil befor it can be furtherprocessed. Crude oil itsel is of littleuse. To get the maximum valuefrom crude, it needs to be refinedand blended in a refinery into morevaluable and useful petroleum prod-ucts: fuels, lubricants, waxes,asphalt, plastics, fibres, detergents,fertilizers and many others.

An oil refinery is a well structuredarrangement of manufacturing pro-cesses designed to perform physicaland chemical changes in crude oil toconvert it stepwise into intermedi-ate and end products. Refinery pro-cesses have been and are continu-ously developed and optimized inresponse to changing marketdemands for certain products.Almost all refineries, regardless oftheir special product scope, use thesame few basic processes like sepa-ration (distillation), conversion andtreating. Cracking belongs to themost common conversion methods.

Process analyzers, mainly processgas chromatographs but also con-tinuous gas analyzers, are standardin a refineries process instrumenta-tion. They deliver key data to pro-cess and product quality control andasset management.Siemens Sensors and Communica-tion provides efficient analyzers,expertise and solutions to this tasks.

Use of Process Analytics forCracking Processes in Refineries


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Crude oil refining at a glance

Refining processThe key objective of the refining processis to effect chemical reactions on theraw hydrocarbons.The refining process from crude oil toend-use products comprises severalsub-processes (fig. 1).

Fractionation

Because crude oil is a mixture of hydro-carbons with different boiling tempera-tures, it can be separated by distillation(fractionation) into groups of hydrocar-

bons (called cuts or fractions) that boilbetween two specified boiling points(fig. 2).Two types of distillation are performed:atmospheric and vacuum. Atmosphericdistillation takes place in a distilling col-umn at or near atmospheric pressureand at temperatures of 90 to 650 C.To recover heavy distillates (residues)drawn off from the bottom of this col-umn, the residue is fed to a second dis-tillation column where the process isrepeated under vacuum, called vacuumdistillation. This allows heavy hydrocar-bons with boiling points up to 800 C to

be separated.Conversion

Conversion processes change the sizeand/or structure of hydrocarbon mole-cules by cracking and rearranging mole-cules to add value. The fractions fromthe distillation towers are transformed

into streams (intermediate compo-nents). These processes include:

Decomposition (dividing) bycatalytic and thermal cracking,

Unification (combining) throughalkylation and polymerization and

Alteration (rearranging) with isomer-ization and catalytic reforming.

The most widely used conversionmethod is called cracking because ituses heat and pressure to "crack" heavyhydrocarbon molecules into lighterones to upgrade products and to yield

more desirable hydrocarbon com-pounds.

A cracking unit consists of one or morereactors and a network of furnaces,heat exchangers and other vessels.

Treatment

Treatment processes (fig. 3) areintended to prepare hydrocarbonstreams for additional processing and toprepare finished products.Treatment includes the removal orseparation of aromatics and naph-thenes as well as impurities and mayinvolve chemical or physical separatione. g. dissolving, absorption or precipita-tion such as desalting, drying, desulfur-izing, sweetening, solvent extraction,etc. Hydrotreating is used to removesulfur and reduce nitrogen and some of

the metals contained in the stream bymeans of hydrogen gas and a catalyst.

Fig. 2 and 3: Crude oil refining, separation by boiling points (left), typical processing steps (right)

Fig. 1: From crude oil to end-use products


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Cracking processes

Cracking is, as already explained, a pro-cess used to convert heavy hydrocarbonfractions obtained by vacuum distilla-tion into a mixture of lighter and moreuseful products (fig. 4).

Catalytic CrackingIn catalytic cracking, the feedstockundergoes a chemical breakdown,under controlled heat (450 to 50 C)and pressure, and in the presence of acatalyst, a substance which promotesthe reaction without itself being chemi-

cally changed. The cracking reactionyields petrol, LPG, unsaturated olefincompounds, cracked gas oils, cycle oil,light gases and a solid coke residue.Cycle oil is recycled to cause furtherbreakdown and the coke, which forms alayer on the catalyst, is removed byburning.

Fluid Catalytic Cracking (FCC)

Fluid catalytic cracking (fig. 6) uses acatalyst in the special form of a very finepowder which flows like a liquid whenagitated by steam, air or vapour. Feed-stock entering the process immediately

meets a stream of very hot catalyst inthe riser and vaporises. The resultingvapours keep the catalyst fluidised as itpasses into the reactor, where thecracking takes place and where it is flui-dised by the hydrocarbon vapour. Thecatalyst next passes to a steam strippingsection where most of the volatilehydrocarbons are removed. The spentcatalyst then passes to a regeneratorvessel where it is fluidised by a mixtureof air and the products of combustionwhich are produced as the coke on thecatalyst is burnt off. The regeneratedcatalyst then flows back to the reactor.

The catalyst thus undergoes a continu-

ous circulation between the reactor,stripper and regenerator sections.

The catalyst is usually a mixture of alu-minium oxide and silica. The introduc-tion of synthetic zeolite catalysts hasallowed much shorter reaction timesand improved yields.

Hydrocracking

Hydrocracking (fig. 8) is catalytic crack-ing in the presence of hydrogen. Theextra hydrogen saturates, or hydroge-nates, the chemical bonds of the

cracked hydrocarbons and creates iso-mers with the desired characteristics.Hydrocracking uses slightly lower tem-peratures and much greater pressure toobtain chemical reactions. Hydrocrack-ing produces no residues, only light oils.

Wax feed is mixed with hydrogen,heated, and sent to a reactor vessel witha fixed bed catalyst, where cracking andhydrogenation take place. Products arethen sent to a fractionator to be sepa-rated. The hydrogen is recycled.

Thermal CrackingThermal cracking uses heat to breakdown the residue from vacuum distilla-tion trough upgrading and visbreakingor to produce light fractions or distil-lates, burner fuel and/or petroleumcoke.

Steam Cracking

Steam cracking is a high-temperatureprocess at 750 to 900 C or more, whichproduces valuable ethylene and otherfeedstocks for the petrochemicalindustry. In steam cracking, a gaseousor liquid hydrocarbon feed like Naphta,LPG or Ethane is diluted with steam and

then very briefly heated in a furnace toaround 850 C. In modern cracking fur-naces, the residence time is reduced to

milliseconds in order to improve the

yield of desired products.After the cracking temperature hasbeen reached, the gas is quicklyquenched to stop the reaction in atransfer line exchanger. The productsproduced in the reaction depend on thecomposition of the feed, the hydrocar-bon to steam ratio and on the crackingtemperature & furnace residence time.The process also results in the slow dep-osition of coke, a form of carbon, on thereactor walls. This degrades the effec-tiveness of the reactor, so reaction con-ditions are designed to minimize this.

Nonetheless, a steam cracking furnacecan usually only run for a few months ata time between de-cokings.

Delayed Coking

Some refineries use the most commondelayed coking process, which oper-ates at lower temperatures (ca. 500 C)and moderate pressure to turn residuesinto lighter products and a hard, coallikesubstance (petroleum coke) that is usedas an industrial fuel and in the produc-tion of electrodes for the steel and alu-minum industries.

Visbreaking

is a non-catalytic thermal process thatconverts atmospheric or vacuum resi-dues via thermal cracking to gas,naphtha, distillates, and visbroken resi-due. Atmospheric and vacuum residuesare typically charged to a visbreaker toreduce fuel oil viscosity and increasedistillate yield in the refinery. The pro-cess will typically achieve a conversionto gas, gasoline, and distillates of 10 %to 50 %, depending on the severity andfeedstock characteristics.

Fig. 4: Cracking principle: one large is cracked into four smaller molecules

Fig. 5: Cracking plant


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Process Analytics in Cracking Plants (1)Measuring tasks and solutions in FFC plants

Allgemeine ZieleIn Anlagen zum Cracken von Rohlstellen Gaschromatographen und kon-tinuierliche Gasanalysatoren wichtigeDaten fr den Prozess zur Verfgung.Die wesentlichen Ziele dabei sind, durchkontinuierliche berwachung der Proz-essstrme auf ihre Zusammensetzungden Anlagenbetrieb hinsichtlichWirkungsgrad und Produktqualitt zusteuern und zu optimieren, Sicherheitfr Personen und Anlage zu gewhrleis-ten sowie abzusichern, dass die nach

entsprechender Behandlung an dieAtmosphre abgefhrten Restemis-sionen innerhalb der zulssigen Gren-zwerte liegen.

Measuring tasks inFluid Calatylic CrackersA simplified flow chart of a fluid cata-lytic cracker (FCC) including typical gassampling locations along the processpath is shown in fig. 6 with correspond-ing analysis details in fig. 7.

The feed (fresh and recycled) is crackedin the reactor using a fluidized catalystwhich is continuously regenerated inthe regenerator. The flue gas leavingthe regenerator passes a waste heatboiler, a particulate matter (PM) andNOx removal plant and is released tothe atmosphere. Liquid products aredrawn off from the fractionator, thegaseous overhead is fed to the vapor

recovery unit for further separation intouseful products.

Fig. 7: Sampling points, measuring tasks and analyzers, correlated to fig. 6

Sampling pointSampling stream

Measuring task Measuringcomponents

Suitable SiemensAnalyzer

1 Flue gas downstream of regenerator Carbon balance(Efficiency of catalysts regeneration)

Nitrogen 1

Oxygen 1+2CO 1+3

CO21+3

MAXUM/MicroSAM 1

OXYMAT 6 ULTRAMAT 6

2 Flue gas downstream of denitrification Emission control(NH3 from denitrification)

NH3 LDS 6

3a/b Gasoline/Light gas oil to blending Boiling point analysis for gasoline purity(Simulated distillation)

All MAXUM

4 Gas to vapor recovery unit FCC unit mass balance and feed forward controlfor VRU control

HydrogenC1 to C5

MAXUM

5 Demethanizer overhead Minimize olefine loss C3=, c4= MAXUM/MicroSAM

6 Fuel gas Minimize olefine loss C2=, C3= MAXUM/MicroSAM

7 Rich sponge oil Reduce recycling of light hydrocarbons iC4 MAXUM/MicroSAM

8 Still gas overhead Reduce impurities in feed to alkylation unit C2, iC4 MAXUM/MicroSAM

9 Rich oil Minimize light hydrocarbons from getting tothe feed to alkylation unit

C2, C3, C4 MAXUM/MicroSAM

10 Debutanized gasoline Monitor butane content(Reid Vapor Pressure, RVP)

iC4, RVP MAXUM

Fig. 6: FCC unit (left) and FCC vapor recovery unit (right), with typical sampling points


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Process Analytics in Cracking Plants (2):Measuring tasks and solutions in Hydrocracking plants

Measuring tasks inhydrocrackersHydrocracking provides great flexibilityregarding acceptance of feed of almostany boiling range and to make productsof any desired type.Fig. 8 shows a simplified flow sheet fora two stage plant. Feed and hydrogenare charged to the first reactor wherecertain compounds are hydrogenatedand cracking is started. Liquids from theseparator are charged to the fraction-ator where some fractions are cut out.

Fractionator bottoms are again mixedwith hydrogen and fed to the secondreactor for further treatment.Analysis details are shown in fig. 9.Plants with more stages and paralleltrains are also common to increasethroughput and quality

Measuring task in avisbreaker (no figure)Typical visbreaker measuring tasks are:

combustion air control and emissionmonitoring at the heater and the frac-tionator (similar to line 6 and 7 in

fig. 9), Oxygen feed and flue gas monitoring

at the fractionator and

fractionator overhead analysis (C2 toC5) using gas chromatography

Measuring tasks in a coker(no figure)Measuring tasks in a coker are quitesimilar to those of sampling point 3 and4 of the hydrocracker as shown in fig. 9.

Measuring tasks in a

steam crackerMeasuring tasks in a steam cracker aredescribed in a separate Case Study(Process Analytics in Ethylene Produc-tion Plants).

Fig. 9: Sampling points, measuring tasks and analyzers, correlated to fig. 8

Sampling pointSampling stream

Measuring task Measuringcomponents

MeasuringRanges [%]

Suitable SiemensAnalyzer

1 Recycle hydrogen Monitor hydrogen ratio to feed(fix limit value for H2)

HydrogenC1C2, C3C4, C5

0 ... 1000 ... 250 ... 20 ... 0,5

MAXUM/MicroSAM

2 Make-up hygrogen Monitor hydrogen ratio to feed;add H2 if recyc. H2 is not sufficient

Hydrogen 0 ... 100 MAXUM/MicroSAM

3 Stabilizer overhead Achieve efficient operation of stabilizer when

monitoring carryover of C5 and heavier(fix limit value for C5s)

i-C5, n-C5

i-C4n-C4C3C2

0 ... 1

0 ... 400 ... 300 ... 400 ... 10

MAXUM/MicroSAM

4A/B Stabilizer bottom Achieve efficient operation of stabilizers whenmonitoring C5+ bottom product

i-C4n-C4

0 ... 10 ... 1

MAXUM

5 Inlet combustion air Combustion control to meet regulatory require-ments for emissions

O2CO

0 ... 210 ... 10

ULTRAMAT 23

6 Inlet combustion air Combustion control to meet regulatory require-ments for emissions

O2CO

0 ... 210 ... 10

ULTRAMAT 23

7 Reactor flue gas Emission monitoring acc. regulatory requirements O2, CO, NOx Regulated ULTRAMAT 23

8 Reactor flue gas Emission monitoring acc. regulatory requirements O2, CO, NOx Regulated ULTRAMAT 23

Fig. 8: Hydrocracker flow diagram with typical sampling points

Fig. 10: MAXUM Prozess-GCin a shelter


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Process Analytics in Cracking Plants (3):Application of MAXUM and ULTRAMAT

Variety and quality of products fromcracking processes depend strongly onparameters such as feed composition,cracking temperature, separation per-formance, process stream compositionetc. Thus, it is essential for process prof-itability and product quality to operatethe cracking plants as close as possibleto the particular optimal process param-eters. Gas chromatography can supportthis objective essentially.

MAXUM controlsprocess conditionsProcess gas chromatography is used tocollect the neccessary informationabout the composition of the processstreams in order to operate the processat optimal conditions, to get high andconstant product quality, to avoid over-cracking, to achieve maximum through-put and to decrease production costs.

Outstanding features

The Siemens MAXUM (fig. 18) is verylikely the most suitable gas chromo-matograph to solve this task. It repre-sents the top technology in process gas

chromatography with outstanding fea-tures resulting in a high versatility tosolve demanding application tasks withbest possible analytical results at lowestcosts. Selected features are:

Multiple analytical tools such asovens, detectors, valves etc.

Parallel chromatography for fastanalysis, system simplification andincrease of reliability

Single and independent dual ovenconcept (fig. 11) for minimizing thenumber of analyzers

Airbath and airless oven to reduce

utility costs Valveless column switching to reduce

maintenance

Complete networking capabilities andpowerful processing software

Parallel Chromatography

MAXUM provides a completelynew approach to gas chroma-tography, named ParallelChromatography.With Maxums hardware andsoftware tools, a complex singletrain analysis can be broken intomultiple, very simple singletrains. Each of the single trains,calledApplets, run in parallel,which reduces cycle time com-pared to a seriell run in conven-

tional chromatographs. This is inparticular important for mea-surements where a shortresponse time is required tomaintain optimal process condi-tions. Applets may be standard-ized for common applicationsand can be configured alone orin parallel groups, depending onthe actual application task.

Simulated Distillation

To ensure product quality and to sup-port process control, Simulated Distilla-tion is utilized to characterize the boil-ing point distribution of hydrocarbonmixtures up to a boiling point of 545 Cin compliance with ASTM methods.

The Siemens MAXUM temperature pro-grammable process gas chromatographis designed to perform the SimulatedDistillation measurement in plantsunder process conditions and in electri-cal hazardous areas. Also, its powerful-software system produces the calcu-lated outputs required from a simulateddistillation analyzer (fig. 12).

ULTRAMAT controlsdecoking reactionContinuous gas analysis (NDIR princi-ple) is used to monitor the decokingprocess in order to reduce steam crackerdecoking times and to save mainte-nance costs e.g. through less coilreplacements.

The Siemens ULTRAMAT 6 orULTRAMAT 23 NDIR gas analyzersarevery much suited for this application.

BenefitsOn line monitoring of steam cracker anddecoking reaction allows to:

optimize efficiency by varyingreaction times

avoid and reduce simultaneousshut downs of more than onesteam cracker for decoking

decrease of direct decoking cost

reduction of coil replacements

All together, on-line monitoringthrough process analytics providesthe potenzial to save many millions ofdollars per year in a typical ethyleneplant using steam crackers.

Fig. 11: MAXUM Dual oven concept

Left: split air bath, temperature programmed

Right: dual airless

Fig. 12: MAXUM: Simulated distillation


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Process Analytics in Cracking Plants (4)Application of LDS 6 for NH3 slip monitoring

Application

Cracking process

The purpose of a fluid catalytic crackingunit (FCCU) is to crack heavy moleculesinto lighter and more valuable com-pounds. This is an endothermic processand takes place in a vertical tube reactorwith ascending flow (riser).The feed is preheated and enters theunit at the base and is mixed with hotregenerated catalyst. The feed is vapor-ized and the mix of catalyst and hydro-carbon vapor travels up the riser intothe reactor. After the cracking intolighter products, the spent catalyst isstripped from the hydrocarbons and fedto the regenerator. The hydrocarbonsleave the reactor for separation in a sep-aration column.

Regeneration process

The reaction produces carbon (coke)which remains on the catalyst particleand rapidly lowers its activity. In orderto recover its activity, it is regeneratedby burning off the coke with air.

The flue gas leaving the regenerator

contains a large quantity of CO (carbonmonoxide) which is burnt to carbondioxide in a CO furnace called Wasteheat boiler to recover the availableheat..

NOx reduction and NH3 slip

The combustion exhaust leaving thewaste heat boiler contains a largeamount of NOx which, due to environ-mental permits, must be reduced tovery low levels anywhere from 50 to1 ppm, before it is released to the atmo-sphere. This is achieved by directing theexhaust through either a selective cata-

lytic (SCR) or a selective non-catalytic(SNCR) reduction unit where NH3 isinjected into the process to react withNOx and form nitrogen and water.However, under real conditions thereaction runs not always perfectly bal-anced and some NH3 can slip throughto the atmosphere, called NH3 slip.

Measur-ing taskMeasuringtask is todeterminecontinuouslythe concen-tration levelof NH3 in theexhaust gasdownstreamof the denitri-fication unit.

SolutionThe SiemensLDS 6 tunablediode laser in-situ gas analyzer (fig. 16)is very much suited to accomplish thistask. It routinely measures NH3 in arange as low as 0 to 10 ppm.A single LDS 6 analyzer is able to moni-tor gas concentrations in up to threemeasurement points simultaneously.In the actual application, either inho-mogenities in the catalyst efficiencythroughout the cross section can be

monitored by using several measure-ment channels. Alternatively, morethan one DeNOx column can be moni-tored with only one central unit.

The LDS 6 is installed in-situ directlydownstream the catalyst, see fig.13.

User benefitsOptimizing the SCR/SNCR process bycontrolling the NH3-slip means: reducing the consumption of

ammonia or urea

keeping the legislative thresholdvalues for NH3 if required

stabilizing the process and avoidingpeak emissions

minimizing technological drawbacks,increasing DeNOX efficiency

reducing the total nitrogen - NH3 andNOx - emission.An optimized process input is thebase of minimized emission.

The SCR processNitrogen oxides (NOx) formed incombustion processes are efficientlyreduced to water and nitrogen in theselective catalytic reduction (SCR) pro-cess. Ammonia (NH3) or ureaCO(NH2)2 is introduced to the fluegases upstream of a heterogeneouscatalyst where the reduction takesplace. The SCR process is normallyoperated in the temperature range of300 to 400 C.

The SNCR processFor the selective non catalytic reaction(SNCR) process, ammonia (NH3) orurea CO(NH2)2 is introduced to theflue gases in the hot combustion zonewhere the reduction of NOx takesplace spontaneously. Depending onthe type of the reducing agent, theSNCR process is typically operated inthe temperature range of 800 C to950 C.At temperatures below the optimumtemperature, the reaction rate is tooslow, resulting in an inefficient NOxreduction and too high ammonia slip.Above the optimum temperature, theoxidation of ammonia to NOxis getting significantly high and theprocess tends to produce NOx insteadof decreasing it.

Fig. 13: NH3 slip measurement in FFC flue gas


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Siemens Process Analytics at a glanceProducts

Siemens Process AnalyticsSiemens Process Analytics is a leadingprovider of process analyzers and pro-cess analysis systems. We offer our glo-bal customers the best solutions fortheir applications based on innovativeanalysis technologies, customized sys-tem engineering, sound knowledge ofcustomer applications and professionalsupport. And with Totally IntegratedAutomation (TIA). Siemens ProcessAnalytics is your qualified partner forefficient solutions that integrate pro-

cess analysers into automations sys-tems in the process industry.

From demanding analysis tasks in thechemical, oil & gas and petrochemicalindustry to combustion control inpower plants to emission monitoring atwaste incineration plants, the highlyaccurate and reliable Siemens gas chro-matographs and continuous analyserswill always do the job.

Siemens process Analytics offers a wideand innovative portfolio designed tomeet all user requirements for compre-hensive products and solutions.

Our ProductsThe product line of Siemens ProcessAnalytics comprises extractive and in-situ continuous gas analyzers (fig. 14 to17), process gas chromatographs(fig. 18 to 21), sampling systems andauxiliary equipment. Analyzers andchromatographs are available in differ-ent versions for rack or field mounting,explosion protection, corrosion resis-tant etc.

A flexible networking concept allowsinterfacing to DCS and maintenance

stations via 4 to 20 mA, PROFIBUS,Modbus, OPC or industrial ethernet.

Fig. 14: Series 6 gas analyzer (rack design)

Fig. 15: Product scope Siemens Continuous Gas Analyzers

Extractive Continuous Gas Analyzers (CGA)

ULTRAMAT 23 The ULTRAMAT 23 is a cost-effective multicomponent analyser for themeasurement of up to 3 infrared sensitive gases (NDIR principle) plusoxygen (electrochemical cell). The ULTRAMAT 23 is suitable for a widerange of standard applications. Calibration using ambient air eliminatesthe need of expensive calibration gases.

CALOMAT 6/62 The CALOMAT 6 uses the thermal conductivity detection (TCD) methodto measure the concentration of certain process gases, preferably hydro-gen.The CALOMAT 62 applies the TCD method as well and is speciallydesigned for use in application with corrosive gases such as chlorine.

OXYMAT 6/61/64 The OXYMAT 6 uses the paramagnetic measuring method and can beused in applications for process control, emission monitoring and qualityassurance. Due to its ultrafast response, the OXYMAT 6 is perfect formonitoring safety-relevant plants. The corrosion-proof design allowsanalysis in the presence of highly corrosive gases.

The OXYMAT 61 is a low-cost oxygen analyser for standard applications.The OXYMAT 64 is a gas analyzer based on ZrO2 technology to measuresmallest oxygen concentrations in pure gas applications.

ULTRAMAT 6 The ULTRAMAT 6 uses the NDIR measuring principle and can be used inall applications from emission monitoring to process control even in thepresence of highly corrosive gases.ULTRAMAT 6 is able to measure up to 4 infrared sensitive components ina single unit.

ULTRAMAT 6 /OXYMAT 6

Both analyzer benches can be combined in one housing to form a multi-component device for measuring up to two IR components and oxygen.

FIDAMAT 6 The FIDAMAT 6 measures the total hydrocarbon content in air or even inhigh-boiling gas mixtures. It covers nearly all requirements, from tracehydrocarbon detection in pure gases to measurement of high hydrocar-bon concentrations, even in the presence of corrosive gases.

In-situ Continuous Gas Analyzer (CGA)

LDS 6 LDS 6 is a high-performance in-situ process gas analyser. The measure-ment (through the sensor) occurs directly in the process stream,no extractive sample line is required. The central unit is separated fromthe sensor by using fiber optics. Measurements are carried out in real-time. This enables a pro-active control of dynamic processes and allowsfast, cost-saving corrections.

Fig. 16: Series 6 gas analyzer (field design) Fig. 17: LDS 6 in-situ laser gas analyzer


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Siemens Process Analytics at a glanceProducts (continued) and Solutions

Fig. 18: MAXUM edition II Process GC

Fig. 19: MicroSAM Process GC

Fig. 20: SITRANS CV Natural Gas Analyzer

Our solutionsAnalytical solutions are always drivenby the customers requirements. Weoffer an integrated design covering all

steps from sampling point and samplepreparation up to complete analysercabinets or for installation in analysershelters (fig. 22). This includes also sig-nal processing and communications tothe control room and process controlsystem.

We rely on many years of world-wideexperience in process automation andengineering and a collection of special-

ized knowledge in key industries andindustrial sectors. We provide Siemensquality from a single source with a func-tion warranty for the entire system.

Read more in "Our Services.

Fig. 22: Analyzer house (shelter)

Process Gas Chromatographs (Process GC)

MAXUM edition II MAXUM edition II is very well suited to be used in rough industrial envi-ronments and performs a wide range of duties in the chemical and pet-rochemical industries and refineries.

MAXUM II features e. g. a flexible, energy saving single or dual oven con-cept, valveless sampling and column switching, and parallel chromatog-raphy using multiple single trains as well as a wide range of detectorssuch as TCD, FID, FPD, PDHID, PDECD and PDPID.

MicroSAM MicroSAM is a very compact explosion-proof micro process chromato-graph. Using silicon-based micromechanical components it combinesminiaturization with increased performance at the same time.

MicroSAM is easy to use and its rugged and small design allows mount-ing right at the sampling point. MicroSAM features drastically reducedcycle times, provides valveless sample injection and column switchingand saves installation, maintenance, and service costs.

SITRANS CV SITRANS CV is a micro process gas chromatograph especially designedfor reliable, exact and fast analysis of natural gas. The rugged and com-pact design makes SITRANS CV suitable for extreme areas of use, e.g. off-shore exploration or direct mounting on a pipeline.

The special software "CV Control" meets the requirements of the naturalgas market, e.g. custody transfer.

Fig. 21: Product scope Siemens Process Gas Chromatographs


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Siemens Process Analytics at a glanceSolutions (continued) and Services

Our solutions ...

Analyzer networking fordata communication

Engineering and manufacturing of pro-cess analytical solutions increasinglycomprises "networking". It is getting astandard requirement in the processindustry to connect analyzers andanalyzer systems to a communicationnetwork to provide for continuous anddirect data transfer from and to theanalysers.The two objectives are (fig. 24):

To integrate the analyzer andanalyzer systems seamless into thePCS / DCS system of the plantand

To allow direct access to the analyzersor systems from a maintenancestation to ensure correct and reliableoperation including preventive orpredictive maintenance (fig.23).

Siemens Process Analytics provides net-working solutions to meet the demandsof both objectives.

Our ServicesSiemens Process Analytics is your com-petent and reliable partner world widefor Service, Support and Consulting.

Our rescources for that are

ExpertiseAs a manufacturer of a broad variety

of analyzers, we are very much expe-rienced in engineering and manufac-turing of analytical systems andanalyzer houses.We are familiar with communicationnetworks, well trained in service andmaintenance and familiar with manyindustrial pro cesses and industries.Thus, Siemens Process Analytics ownsa unique blend of overall analyticalexpertise and experience.

Global presenceWith our strategically located centersof competence in Germany, USA,Singapore, Dubai and Shanghai, weare globally present and acquaintedwith all respective local and regionalrequirements, codes and standards.All centers are networked together.

Fig. 24: Networking for DCS integration and maintenance support

Fig. 25: Portfolio of services

Fig. 23: Communication technologies


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Siemens Process Analytics at a glanceServices, continued

Our Services ...

Service portfolio

Our wide portfolio of services is seg-mented into Consulting, Support andService (fig. 25 to 26). It comprisesreally all measures, actions and advisesthat may be required by our clientsthroughout the entire lifecycle of theirplant. It ranges from site survey toinstallation check, from instruction ofplant personnel to spare part stock man-agement and from FEED for ProcessAnalytics (see below) to internet-basedservice Hotline.

Our service and support portfolio(including third-party equipment) com-prises for example:

Installation check

Functionality tests

Site acceptance test

Instruction of plant personnel on site

Preventive maintenance

On site repair

Remote fault clearance

Spare part stock evaluation

Spare part management

Professional training center

Process optimisation

Internet-based hotline

FEED for Process Analytics

Technical consullting

FEED for Process Analytics

Front End Engineering and Design(FEED) is part of the planning and engi-neering phase of a plant construction ormodification project and is done afterconceptual business planning and prior

to detail design. During the FEED phase,best opportunities exist for costs andtime savings for the project, as duringthis phase most of the entire costs aredefined and changes have least impactto the project. Siemens Process Analyt-ics holds a unique blend of expertise inanalytical technologies, applicationsand in providing complete analyticalsolutions to many industries.

Based on its expertise in analytical tech-nology, application and engineering ,Siemens Process Analytics offer a widescope of FEED services focused on anal-ysing principles, sampling technologies,application solutions as well as commu-nication system and given standards (allrelated to analytics) to support our cli-ents in maximizing performance andefficiency of their projects.

Whether you are plant operators orbelong to an EPC Contractor you willbenefit in various ways from FEED forProcess Analytics by Siemens:

Analytics and industry know howavailable, right from the beginningof the project

Superior analyzer system perfor-mance with high availability

Established studies, that lead to

realistic investment decisions Fast and clear design of the analyzer

system specifications, drawings anddocumentation

Little project management andcoordination effort, due to oneresponsible contact person andless time involvement

Additional expertise on demand,without having the costs, the effortand the risks of building up the capac-ities

Lowest possible Total Costs of Owner-ship (TCO) along the lifecycle regard-

ing investment costs, consumptions,utilities supply and maintenance.

Fig. 26: Portfolio of services provided by Siemens Process Analytics


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If you have any questions, please contact your local sales representative or any of the contact addresses below:

Siemens AGA&D SC PA, Process Analyticsstliche Rheinbrckenstr. 5076187 KarlsruheGermany

Phone:+49 721 595 3829Fax: +49 721 595 6375E-mail:[email protected]/prozessanalytics

Siemens Ltd., ChinaA&D SC, Process Analytics7F, China Marine TowerNo.1 Pu Dong AvenueShanghai, 200120P.R.China

Phone:+86 21 3889 3602Fax: +86 21 3889 3264E-mail: [email protected]

Siemens Energy & Automation Inc.7101 Hollister RoadHouston, TX 77040USA

Phone:+1 713 939 7400Fax: +1 713 939 9050E-mail: [email protected]

www.siemens.com/processanalytics

Siemens LLCA&D 2B.PO Box 2154,Dubai, U.A.E.

Phone:+971 4 366 0159Fax: +971 4 3660019E-mail: [email protected]/processanalytics

Siemens Pte. LimitedA&D SC PS/PA CoC60 MacPherson RoadSingapore 348615

Phone:+65 6490 8728Fax: +65 6490 8729E-mail: [email protected]

www.siemens.com/processanalytics