Chemical Sensors for the NewSampling/Sensor Initiative

Nelson Lytle

Honeywell International, Inc.

January 11, 2005

Objectives

• Illustrate sensor/composition/property measurement concept with examples

• Discuss potential NeSSI sensor cluster applications

• Invite sensor developers to participate• Increase the applicability of NeSSI as a

sensor platform• Get tools into chemist’s and engineer’s hands

The Ten NeedsChemical/Composition/Property

• Bio Assay• Chemical Composition• Cleaning Validation• Coating Consistency• Mixing Efficiency

• Moisture Concentration• Particle Sizing• Vapor Characterization• Viscosity/Rheology• Waste Minimization

Mel Koch, CPAC

Major Goals of NeSSI

• Modular, miniature, smart sample system• Based on ISA SP76 standard• Field mounted• Open connectivity for communications• Integration of sample system with

physical/chemical sensors• Technology bridge to process for micro-

analytical devices

NeSSI: Enabler for Micro Analytical(the “rail” concept)

Standard Mechanical Interface “Rail”

Standard Electrical (Digital) Interface “Rail”

Anyone’s Sensor Anyone’s Actuator

SAM*

Standard “hockey- puck

PC”P

V

*Sensor/Actuator Manager

Standard“connectivity”

Desirable Properties Sensor Wish List

• Global electrical (hazardous) certifications• Plug & Play (self-identifies)• Robust (> 99.9% uptime)• Self checking/calibrating/correcting• Low cost (<$5K)• Suitable for operating as a Functional Clusters• Gas and/or Liquid Service • Fast (continuous) Response (< 10 seconds)• Physically small in size • Low Power (for intrinsic safe operation)• Low/No Utility or Reagent Usage

Simple Sensors - The Dirty Dozen

• Density• Refractive Index• Viscosity• Optical Absorbance• Dielectric• Conductivity

• pH/ISE/ORP• Turbidity• Thermal Conductivity• Ultrasonic• Moisture• Gas Specific

Characteristics: simple, dedicated, robust, commonly used.

Deacon Reaction2HCl + 1/2 O2 = Cl2 + H2O

Step 1: HCl(g) reacts with metal oxide (MO) catalyst to produce MCl and H2O(g)

Step 2: O2(g) reacts with MCl to produce MO and Cl2(g)

Thermal ConductivityHe: 222.3N2: 38.3O2: 41.0Cl2: 18.0HCl: 24.0H2O: 35.7

UV Absorbance: Cl2 @ 350 nm

This process can be controlled using thermal conductivity and a UV-Vis absorbance sensor.

Polymerization Control

Monitor molecular weight via density, RI, and viscosity.

Use density or RI for low Mw and viscosity for high Mw.

Mol Wt vs Viscosity

0

20000

40000

60000

80000

100000

120000

0 50000 100000 150000

Mol Wt

Visc

osity

1/Mw vs Density, RI

0.000

0.200

0.400

0.600

0.800

1.000

1.200

0.0000 0.0010 0.0020 0.0030 0.0040 0.0050 0.0060 0.0070

1/Mw

Dens

ity (g

/ml)

1.3700

1.3750

1.3800

1.3850

1.3900

1.3950

1.4000

1.4050

RI

Unsaturation in Edible Oils

NIR absorbance can be used to monitor unsaturation in edible oils. But so can density and RI.

Iodine Value vs RI and Density

1.466

1.468

1.47

1.472

1.474

1.476

80 90 100 110 120 130 140 150

Iodine Value

RI

0.9080

0.9100

0.9120

0.9140

0.9160

0.9180

0.9200

0.9220

Den

sity

Iodine Value vs 889 and 930 nm Absorbance

0.380

0.390

0.400

0.410

0.420

0.430

0.440

0.450

80 90 100 110 120 130 140 150

Iodine Value

889

nm

Ab

s

0.100

0.110

0.120

0.130

0.140

0.150

930

nm

Ab

s

0

.1

.2

.3

.4

.5

750 800 850 900 950 1000 1050 1100

Counts / Nanometers Overlay X-Zoom CURSOR

File # 1 = 1544D2 6/21/2004 7:20 PM Res=0

Edible Oil Classification

Use density, RI, viscosity, optical absorbance to classify oils.

-0.5

0

0.5

-4 -3 -2 -1 0 1 2 3 4 pca eo 7-19-04, X-expl: 98%,2%

soybean

olive

corn w

peanut

canola csafflower

sunflower

corn m

canola m

olive ev

soy/canola

corn/canola

PC1

PC2 Scores

-0.2

0

0.2

0.4

0.6

0.8

1.0

-0.4 -0.3 -0.2 -0.1 0 0.1 0.2 0.3 0.4 pca eo 7-19-04, X-expl: 98%,2%

iodine value889.92 abs

930.98 abs

viscosity

RI

density

PC1

PC2 X-loadings

Simple sensors can monitor blending and determine quality of edible oils.

NeSSI Sensor Clusters

• Boiler Water– Conductivity– pH– pNa

• Waste water– pH– TOC

– O2

Sensors include pH, ISE, ORP, conductivity, UV absorbance.

Water Monitoring:

NeSSI Sensor Clusters

• NOx

• SOx

• O2

• CO

Potential sensors include specific gas sensors, UV-Vis, and IR.

Continuous Emission Monitors:

Use NeSSI advantages of P,T,F control and filtration.

Jet Fuel Properties:

• Density• Flash point• Freezing point• Fuel system icing

inhibitor• Aromatics

Sensors include density, RI, turbidity, NIR/IR absorbance.

NeSSI Sensor Clusters

What am I proposing?

• Simple sensors provide a way to perform analyses that are useful for process control and optimization

• These are measurements that are being used today

• Simply adapt them to the NeSSI standard

Conclusion

• I hope that I have made you aware of the opportunity to use simple, robust sensors to make chemical and property measurements.

• I hope to motivate sensor developers to make sensors available that meet the NeSSI standard.

Everything is in place to make it happen.

Come on in … the water’s fine.

FIN