Sievers InnovOx TOC Analyzers 2
@ 2013, GE Analytical Instruments
• Process TOC Product Introduction• Industry and Application Overview• Key Applications• Case Studies
Agenda
Sievers InnovOx TOC Analyzers 4
@ 2013, GE Analytical Instruments
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
Sievers InnovOx TOC Analyzers 6
@ 2013, GE Analytical Instruments
GE’s Sievers TOC Analyzer & Sensors Line
Sievers InnovOx TOC Analyzers 7
@ 2013, GE Analytical Instruments
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
Sievers InnovOx TOC Analyzers 9
@ 2013, GE Analytical Instruments
Sievers InnovOx TOC Analyzer: Industries
Hydrocarbon Processing
Microelectronics
Food & Beverage
PharmaceuticalMunicipal Water and Wastewater
Chemical Processing
Sievers InnovOx TOC Analyzers 10
@ 2013, GE Analytical Instruments
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
Sievers InnovOx TOC Analyzers 11
@ 2013, GE Analytical Instruments
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
Sievers InnovOx TOC Analyzers 12
@ 2013, GE Analytical Instruments
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.
Sievers InnovOx TOC Analyzers 13
@ 2013, GE Analytical Instruments
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
Sievers InnovOx TOC Analyzers 14
@ 2013, GE Analytical Instruments
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
Sievers InnovOx TOC Analyzers 15
@ 2013, GE Analytical Instruments
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
Sievers InnovOx TOC Analyzers 16
@ 2013, GE Analytical Instruments
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
Sievers InnovOx TOC Analyzers 17
@ 2013, GE Analytical Instruments
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.
Sievers InnovOx TOC Analyzers 19
@ 2013, GE Analytical Instruments
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
Sievers InnovOx TOC Analyzers 20
@ 2013, GE Analytical Instruments
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.
Sievers InnovOx TOC Analyzers 21
@ 2013, GE Analytical Instruments
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.
Sievers InnovOx TOC Analyzers 22
@ 2013, GE Analytical Instruments
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.
Sievers InnovOx TOC Analyzers 23
@ 2013, GE Analytical Instruments
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.