Cemtek User Group MeetingABB Analytical Measurement

3rd October 2014

Introduction

Steve GibbonsBusiness Development Manager – CEMS

ABB Inc. (Measurement Products)Tel: +1 (215) 292-8589

Email: stephen.gibbons@us.abb.com

Agenda CEMTEK / ABB relationship ABB Continuous Gas Analyzers Overview of select few products LGR Off-Axis ICOS technology Applications for Off-Axis ICOS Questions?

12/12/2014 | Slide 2

CEMTEK / ABB relationship

CEMTEK Contracted ‘System Integrator’ since March 2014

Certified service partner

Customer focused

Responsive and skilled service organization

Capable/active to introduce ‘new’ technologies – e.g. OA-ICOS

ABB Extensive product portfolio…

GC, FTIR, NDIR, NDUV, PMD, TCD, FID, Zirconia, TDL, OA-ICOS …

…serving all major industriesOil, Gas & Petrochemicals, Chemicals, (Power), Cement, Iron & Steel, Pulp & Paper, Glass, Aluminum, Pharmaceuticals, Marine …

12/12/2014 | Slide 3

place picture here

ABB Continuous Gas AnalyzersFormerly ‘Hartmann & Braun’Established 130 years ago

1938 – First Usable NDIR-Process-Spectrometer

Karl LuftErwin Lehrer

The defining moment of non-dispersive infrared photometers came from Erwin Lehrer and Karl Luft.

Two product linesAdvance Optima and EasyLine

Price

Perf

orm

ance

12/12/2014 | Slide 6

Advance OptimaAvailable analyzer modules

IR Photometer

Uras26

Paramagnetic Oxygen

Magnos206

Thermal Conductivity

Caldos27

Trace Oxygen

ZO23

UV / IR Photometer

Limas11

Thermal Conductivity

Caldos25

Flame-ionization detector

MultiFID14 (NMHC)

Paramagnetic Oxygen

Magnos27The Advance Optima series is based on an integrated system concept

Standardized analyzer modules can be combined to a multi-analyzer system

via

Eth

erne

t

Tunable Diode Laser

LS25

Advance OptimaInnovative modular analyzer technology

Common system controller

Measures up to 6 gas components

One central unit - 4 analyzer modules

Analyzers can be operated at a distance of 350 m from the central unit

Sample conditioning system signals can also be integrated on network

Internal PLC functionality- Valve control – autocal, stream switching- Calculations – O2 correction, Wet to Dry- Integrate external signals- Cross sensitivity correction- Program soft keys (i.e. shortcuts)

350 m

Module 1

Module 2 Module 3

Module 4

Module 1

Module 2 Module 3

Module 4

Practical Applications

Simplified system integration Minimize hard-wired cabling = time and cost savings Common spare parts

Internal correction / calculations For example, CH4 interferes with H2 measurement (e.g. Steel Top-Gas) All measuring values connected by common controller (via ext. signals possible)

Swap and change modules / controllers Multiple applications, multiple analyzers in one plant (e.g. Cement, Petrochem) Controller fails on critical application Swap out non-critical analyzer and replace module

Add additional measuring component(s) – (e.g. CEMS, new regulations) Purchase module only and add to existing system

19” rack to Wall Mount housing conversion Purchase new housing, move internal components

Modular System

12/12/2014 | Slide 9

EasyLine So smart, they’re simple

ABB’s entrance into gasanalysis

Proven and reliablemeasurement technologyas in Advance Optima

Two different housingversions with a protectionup to IP65 (NEMA 4 eq.)

Intuitive and easy operation

12/12/2014 | Slide 10

Key benefits EasyLine Easy solution for many applications

Excellent price-performance ratio

Measures up to 5 components in one unit

Combines up to 2 sensors in one enclosure

Top-gas (CO, CO2, CH4, H2)

CEMS (CO, NOx, SO2, CO2, O2)

Uras26

Uras26

Uras26

Electrochemical O2 Sensor

Magnos206 Magnos206

Limas23

Limas23

Electrochemical O2 Sensor

Caldos27

12/12/2014 | Slide 11

Calibration CellsAvailable for all ABB photometers (NDIR, UV, FTIR)

Patented glass to metal welding technique

Filled with real test gas then sealed

20 years experience in production

Applied more than 25,000 times

Stability confirmed by independent testing laboratory

More than 10 years test period:

CO, CO2, NO, SO2 drift < 0.5 % per year

300

350

400

450

500

1990 1992 1994 1996 1998 2000

CO [ppm]

Analyzer1 Analyzer2

Drift: < 0.3 % / a

Components / Min. Ranges

Components EL3000 AO2000

Standard Optional Standard Optional

CO 0-100ppm 0-10ppm 0-50ppm 0-10ppm

NO 0-150ppm 0-50ppm 0-75ppm 0-25ppm

NO2 0-100ppm 0-50ppm 0-100ppm 0-50ppm

SO2 0-100ppm 0-50ppm 0-100ppm 0-25ppm

CO2 0-100ppm 0-5ppm 0-50ppm 0-5ppm

CH4 0-100ppm 0-20ppm 0-100ppm 0-20ppm

N2O 0-100ppm 0-10ppm 0-50ppm 0-10ppm

O2 0-2vol% - 0-0.5vol% -

H2 (dependent on gas composition) 0-10vol% - 0-3vol% 0-0.3vol%

Guide only – dependent on gas composition

12/12/2014 | Slide 13

© ABB Group August 16, 2012 | Slide 14

LS4000Tunable diode laser analyzer

LS4000 – Laser Gas AnalyzerProduct overview

Analog outputs Digital outputs

Analog inputs (optional)Service Port (Ethernet)

Power supply

Receiver unitTransmitter unit

Junction box

Process purging is applied to keep the

optical windows clean.

The influence of temperature and

pressure variations is eliminated by

automatic dynamic correction.

In-situ, non-contact measurement with fast

response (~2 sec)

Suitable for temp. < 2732oF and pressures

up to 290 psi

Compact & flameproof (Ex-d)

housing approved for Class1 Div1

hazardous areas. Purging flange

Measurement of O2 (Vol%)

Interior design with minimal air space –no N2 purging for most applications

12/12/2014 | Slide 15

place picture here

ACF50004th generation FTIR based CEMS

ACF50004th generation FTIR based CEMS

1993

Cemas-FTIR

1996Advance

Cemas-FTIR

2002

ACF-NT

2013

ACF5000

More than 1,500 installations worldwide! 12/12/2014 | Slide 17

Test gas

CompressedAir

Gas Outlet

Sample Gas

FTIR

FID

O2

ASP - Block

MRCell

AirCleaner

Emergency purgeTest gas

Test gas

Burner Gas

ExhaustAnalyzer≥ 356°F

Sample Conditioning≥ 356°F

Sample Line ≥ 356°F

Sampling≥ 356°F

Stack

ACF5000Close-coupled design ensures no cold spots

12/12/2014 | Slide 18

Electronic Box - Amplifier- Solenoid valvesRemote Service Unit

Gas Cell Box- Sample cell- Gas feeding - Fidas24 and ZrO2 Sensor

Interferometer Box

Electronic Box - FTIR

Air Cleaner Box

I/O Interface

Power Distribution

Instrument Air Distribution

Systemcontroller

Pre-engineered systemAll analyzers manufactured by ABB

12/12/2014 | Slide 19

ABB Bomem FTIR Spectrometer

FTIR technology Drift free, virtually no recalibration

High resolution spectrometer (1cm-1) Lower detection limit and cross interference

Thermo-electrically (TE) cooled detector (DTGS) Improved sensitivity

Split architecture (gas path separated from electronics & optics) Better internal components protection Non-hygroscopic ZnSe beam splitter – insensitive to humidity

Long life optical components Solid state laser (20 years lifetime) IR light source (5-10 years lifetime)

12/12/2014 | Slide 20

ACF5000Optional Validation Unit

Films and gas cells for all FTIR components as a surrogate for test gas

Allows on-going system validations

Can be triggered manually or automatically

Benefits No specialist required to validate measurement

Useful maintenance tool for plant technicians

Very quick and requires no cylinder gases

Future proof technology

Measure up to 15 measuring components

Add measuring components w/o additional hardware

Integrated FID and Zirconia O2 sensor

Formaldehyde measurement option

THC measurement using FTIR (equivalent to FID)

ACF5000Measuring components and ranges

*) Other ranges on request

ACF5000Measuring Ranges *

Component Method Min. Max.

CO FTIR 60ppm 3200ppm

CO2 FTIR 30vol%

NO FTIR 150ppm 1500ppm

NO2 FTIR 40ppm 300ppm

NH3 FTIR 6ppm 300ppm

N2O FTIR 25ppm 500ppm

SO2 FTIR 25ppm 500ppm

H2O FTIR 40vol%

HCl FTIR 10ppm 125ppm

HF FTIR 3ppm 10ppm

CH4 FTIR 10ppm 300ppm

CH2O FTIR 15ppm

THC FTIR 7.5ppm 150ppm

THC FID 7.5ppm 150ppm

O2 ZrO2 25vol%

12/12/2014 | Slide 22

FTIR CEMS

Participated in trial at Holcim, Ste Genevieve in 2012

A number of issues experienced:

1. Test gas tag values not representative of actual HCl concentration

2. Cold spots at ‘spool piece’ between probe tube and probe filter

3. Spectral interference, resulting in positive offset to HCl

Subsequent visit to site resolved issues 2 and 3 above

Findings and improvements not published in official report

Separate addendum was published by ABB in Dec. 2012

ABB FTIR proven capable of meeting draft Performance Specs.

Returning to same site with new system for repeat trial (Jan 2015)

Practical Experience

12/12/2014 | Slide 23

HCl losses around Sample Probe

12/12/2014 | Slide 24

Trend HCl ABB and Company X

HCl_Company X

HCl_ABB

Com

pany

X

Corrective Actions

12/12/2014 | Slide 25

• Special adaptor piece between probe tube and filter housing

• Insulated the flange• Increased probe temp. to 390degF

Note:Permanent installation likely to have suitable flange available.

Spectral Interference

Analysis found Formaldehyde present (0-5ppm)

Resulted in spectral residuals in region HCl measured

Corrective Action

Method for Formaldehyde measurement implemented 0.4ppm offset remained

Data reprocessed using new method for HCl Further improvement – interference at acceptable level

Retrofit solution available for current model

Improved method implemented in 4th generation FTIR system

0.8ppm offset to HCl

12/12/2014 | Slide 26

Results after Corrective ActionsVery good agreement at upper and lower levels

12/12/2014 | Slide 27

Los Gatos Research (LGR)Off-Axis ICOS technology

Founded in 1994, acquired by ABB in October 2013 Located in Silicon Valley (Mountain View, California)

46 Employees (Up from 32 in 2013)- 14 Ph.D. scientists

Adds innovative gas analytical measurement and enhanced laser capabilities to expand ABB’s measurement products in oil and gas, electric power and other industrial sectors

Unique laser absorption technology called Off-Axis Integrated Cavity Output Spectroscopy (OA-ICOS)

First developed Cavity Ring Down Spectroscopy (CRDS) in 1988 by Anthony O’Keefe (founder of LGR)

4th generation delivers superior performance, and is orders-of-magnitude less sensitive to internal alignment of components and to variations in local temperature and pressure

Los Gatos ResearchOff-Axis ICOS technology

12/12/2014 | Slide 29

Conventional TDLASOverview

12/12/2014 | Slide 30

• TDLAS: direct measurement of concentration with minimal calibration• Provides fast gas-specific measurements with no consumables• Ideal for monitoring in hostile conditions• Industry recognizes TDLAS for O2, NH3, HCl, CH4, H2S• ‘Single pass’ conventional TDLAS may not provide sufficient sensitivity

Beer-Lambert Law: I/Io = 1-exp(Leff)I/Io = change in laser intensity() = absorption coefficientLeff = effective optical path length

Limitations of various types of Conventional TDLASLimited to gas matrices with little or no background absorption

12/12/2014 | Slide 31

Limited sensitivity due to: Significant signal/noise issues Resistant light source/laser noise (RIN) Short path lengths

Nonlinear at high concentrations (ppm - %v) Cross interferences and false positives Limited dynamic range Optical bench & TX/RX alignment issues

Manufacturing complexity OPGD configuration concern

Sensitive to vibration and obscuration Internal component reliability External “air blower” mechanisms

Optical cavity provides longest effective path length of any laser analyzer available (up to 15 miles or longer)

Very robust – exact optical bench alignments are not critical

Mirrors cleaned in the field in <20 minutes! OA-ICOS can be employed at any

wavelength from UV to mid-IR LDL’s generally @ 1-50 ppb in complex

matrices and as low as 200ppt range for some gases in ambient air

Single and Dual lasers in single cavity for multi-species detection

Setup for LGR’s patentedOff-Axis ICOS technique

LGR’s solution: Off-Axis ICOSCombines high resolution absorption with long path lengths

12/12/2014 | Slide 32

Cavity Enhanced Absorption Spectroscopy (CEAS)Measures high-resolution spectra, yields accurate data

12/12/2014 | Slide 33

Measures baseline, absorption, detector offset and Ring down time in every scan to confirm path length at every data point!

Scan laser at 100-1000 Hz, measurements every 1-10 ms.Averaging ~ 1 sec of data (typical)

Cavity pressure at 1/10 to 1/15 of 1.0 Atmosphere

Operating at lowerthan ambient pressure narrows spectral peaks and improves Voigt Profile for “fit”

“Chemometrics fit” mode enables quantification of multiple gases in complex mixtures simultaneously with main component Voigt fit

Enables single-laser instrument to accurately report multiple gas species for best value proposition

Facilitates challenging process petrochem/chemical applications

CEAS: Unique ability for multiple integration capabilityHighly resolved Voigt fit integration plus Chemometrics fit

12/12/2014 | Slide 34

LGR Analyzers for Industrial Applications: On-board Storage of Direct Spectra Provides Validation

12/12/2014 | Slide 35

OA-ICOS is a first-principles direct measurement that “proves” the measurement using live and/or recorded spectra to“validate”analyzer response. Confirm and/or troubleshoot process and emissions events On board storage load is variable with data collection rates.

Experimental SetupSimple, robust, serviceable

12/12/2014 | Slide 36

Off-Axis ICOSPackaging Options

Portable 19” Rack 19” RackExperimental setup Standard version Temp. stabilized version

Demonstrates how Sufficient for most Peltier cooler maintainsrobust the technology is applications unless trace constant temp. for optimum

ppb or high ambient temp. performance

12/12/2014 | Slide 37

FAST Acetylene in Ethylene for effective Process Control strategies.

End Users need Class 1, Division 2.

LGR looking for Customer Partner Evaluation sites

Application is not Beta – only the enclosure

Expectation is OA-ICOS could perform with as much as an order of magnitude better sensitivity than any other option

Oil & Gas (Refining, Chem/Petrochem) Acetylene in Ethylene

12/12/2014 | Slide 38

ICOS Faster than GC enabling active control of ethylene process

No mirror fouling or misalignment issues

OEM for Yokogawa since 2007

LGR advanced OA-ICOS as much as an order of magnitude more sensitive!

Acetylene + Methyl Acetylene in EthyleneAcetylene @ ~1000 ppm, Methyl Acetylene @ ~5000 ppm

12/12/2014 | Slide 39

Multi-gas measurements simultaneously in complex flows LGR analyzer uses patented Off-Axis ICOS with chemometric data analysis Spectra provides stored verification of observed events and phenomena

Trace Ammonia in Ethylene

Laboratory feasibility studies show performance for diluted sample calculated to produce signal @ 0.725 ppm

Expectations for process stream performance at 2-5 x better sensitivity with attention to flow control and stable sample conditions

720-730 ppb NH3 in 78% Ethylene, 22% Nitrogen

12/12/2014 | Slide 40

Performance of OA-ICOS; H2S, NH3 with H2O & CO2

Detection of H2S + NH3 with CO2 and H20 – ONE laser H2S = 702.1 ppb, NH3 = 12.64 ppb

ONE laser - multiple gases

12/12/2014 | Slide 41

Applications include: HCl, NH3, CH4, CO, CO2, O2

System configured with or without Dilution, and for Pre-or Post scrubber operations

CEMS Installations; CO, CO2, O2, H2OHCl, HF and NH3 for unique requirements

12/12/2014 | Slide 42

OA-ICOS for HCl CEMS

Combination of HCl and H2O gives added confidence in HCl measurement – usually clear if H2O values are feasible

Possible to combine HCl, NH3 and H2O in one analyzer

Compatible with dilution systems up to 150:1

Also suitable for retrofit to Mercury CEMS

Visualization of spectra very powerful diagnostic tool

Optical cavity can be serviced on-site with minimal training, ensuring maximum availability

LGR HCl/H2O analyzer has been successfully tested on two different U.S. coal-fired power plants- Combined with Mercury CEMS (35:1)- Combined with dilution-extractive CEMS (100:1)- Further trials planned – 150:1, 400-500ft sample line

Excellent solution for MATS compliance

12/12/2014 | Slide 43

Performance of OA-ICOS; Extractive Ammonia

Recovery from 0.1819 ppm NH3 to 0 Air = 13.7 seconds External pump w/ Flow Rate = 1.5 liters/min “Moist” sample & Wetted surfaces reduce memory Dilution reduces extent of memory retention High Performance NH3 MDL of 0.60 ppb

Stack Gas 100X Dilution, measuring 181.9 ppb

12/12/2014 | Slide 44

Performance of OA-ICOS; HF

HF+HCl Dual Laser and Portable configurations available NH3, CO2, CO, O2, H2O SO2 also.

Ambient Air Leak Detection, 0.20 ppb

12/12/2014 | Slide 45

LGR OA-ICOS Laser Analyzers: Value Proposition

OA-ICOS provides most reliable, accurate & precise spectra and integration data -both retained in the analyzer

Zero & Span Calibration not required. Bump Test Verification check performed at the Analyzer in the Shelter

No alignment of any kind is ever required, no dust/obscuration concerns

Dilution & highest dynamic range affords wide range of stream composition tolerance

Reliable, Accurate, Easy and Economical COO

12/12/2014 | Slide 46

Proposed PM Schedule:

Calibration: Not Required

Verification: Monthly is recommended

Clean Mirrors

1X Annually (20 min.)

Replace Flow Pump Diaphragm

1X per 5 years (30 min)

Thank you…

12/12/2014 | Slide 47