#165 - Nova Analyzers from the Field – Episode 3

These pictures had us scratching our heads for a while. The analyzer installation is on a roof in South Africa at a plant that produces aluminum chlorohydrate. According to Wikipedia, aluminum chlorohydrate is used in deodorants and anti-perspirants and as a coagulant in water purification. This South African plant makes it in a reactor containing aluminum ingots, hot water, and aluminum chloride solution.

One by-product of the reaction is hydrogen and that is the gas they wanted to monitor on this site. Possibly because the concentration of H2 is an indicator of the pace of the reaction. High or low H2 content may trigger an adjustment in the addition rate of the aluminum chloride or the aluminum ingots.

The Nova analyzer is easy to identify. It’s the cabinet with the round port-hole, in the center of each picture. This is a Model 430N7MC Hydrogen analyzer with explosion-proof cabinet.

The other components attached to it were more difficult to identify. These were evidently the work of the original installer. From the site staff explanation, there is apparently a vortex-style cooler, a ‘silencer’, and a knock-out pot. We assume that the vortex cooler is intended to cool the gas and cause the moisture to condense and fall out in the knock-out pot. The ‘silencer’ is perhaps to regulate noise or velocity associated with the compressed air input (?). The intentions are good, but the implementation seemed questionable.

A vortex style cooler separates cold and hot fractions of air by spinning them very quickly. They require an input of compressed air in the side, and the hot and cold flows usually emerge from opposite ends of the tube. None of the components in the pictures seem to have that exact configuration. So we were uncertain about the correct operation of the installation.

We were also somewhat confused by the requirement for an explosion-proof analyzer. The components installed ahead of the analyzer do not seem to reflect this requirement.

Our concerns with the tubing layout and functionality of the parts were confirmed when it was revealed that the moisture system was not working properly and was allowing corrosion deposits to form in the system. The deposits were also apparently contributing to sporadic Low Flow alarms in the analyzer.

On the right side of the analyzer is a data collection cabinet or control device of some kind. The analyzer is equipped with a 4-20mA output corresponding to the range of gas analysis. This output is no doubt connected to the process control panel. Adjustments are automatically made in response to the hydrogen levels measured.

Last I heard, the plant was looking to resolve their installation problems and expand their chemical production capacity. It would make sense to tidy up the loose components and mount them on a common base plate with an upgraded tubing layout. Sourcing more reliable components may also be necessary.

Despite the questionable installation, we were glad to hear that the hydrogen analyzer was performing satisfactorily. If you have a requirement for H2 measurement in challenging applications, we can likely offer a solution for you too. Hydrogen page on Nova website.

Episode 1 - old portable flue gas with dual CO channel
Episode 2 - portable ppm H2 analyzer for university metallurgical lab

1-800-295-3771

sales at nova-gas dot com

websales at nova-gas dot com

http://www.nova-gas.com/
https://twitter.com/NOVAGAS
http://www.linkedin.com/company/nova-analytical-systems-inc-
http://www.tenovagroup.com/

Vortex tube graphic modified from:

http://en.wikipedia.org/wiki/Vortex_tube

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#164 - PPM O2 Analysis – Part 1

We have had quite a few inquiries lately about oxygen analysis in the parts-per-million (PPM) scale.

The ambient air we breathe has 20.95% oxygen (O2) in it. This proportion of O2 is suitable for sustaining many forms of life and biological processes on this planet. However, some processes require atmospheres of low O2 or even trace O2. When verifying the purity of a produced gas, instead of measuring the target gas, it is sometimes best to measure the impurities. If the impurity is known to be O2, measuring the O2 will make good sense. Instead of being stated as a percent (%) O2, some very low O2 atmospheres are stated in parts-per-million (PPM).

Measuring ppmO2 can be a challenge for several reasons:

• PPM measurements require a suitable degree of accuracy and
  precision to be meaningful.
• Not all O2 measurement technologies are sensitive enough to
  function at low ppmO2 levels.
• Ambient O2 is ubiquitous and is difficult to exclude.

In our experience, the electrochemical sensor is most commonly requested by our customers for ppmO2 measurement. In Nova’s product line, this methodology can be used for any range from 0-100 PPM to 0-19,999 PPM O2. The electrochemical sensor provides good sensitivity, accuracy, and speed of response to O2 levels in these ranges.

One disadvantage of electrochemical ppmO2 sensors is their sensitivity to high levels of O2. If a sensor is set up for a range of 0-1,000ppm and it is exposed to ambient air, it will be ‘blinded’ temporarily. The effect is similar to stepping out into bright sunlight after spending time in a low-light environment. An electrochemical sensor may have long recovery time after the exposure for a couple of reasons:

• Chemical recovery of the sensor and removal of high O2
  from the cell’s diffusion layer.
• Purging the excess O2 from the internal sample tubing
  and related components.

Therefore, it is important to avoid exposing the sensor to ambient air. This may not be too difficult with a continuous analyzer that is permanently connected to a low O2 environment. However, a portable analyzer may not have this advantage.

In these analyzers, we internally protect the O2 sensors by purging out the ambient air out before exposing the sensors to the sample. When finished analyzing, we trap the last ppmO2 sample in the sensor before decoupling the analyzer from the process. We do both of these operations by using PURGE / SAMPLE switch on the front panel.

Before the analyzer is exposed to the sample gas,
the switch on analyzer is moved to the PURGE position.
Running the analyzer in this mode allows some time
for the ambient air to purge out of the sample tubing.
After the purge time, the switch can be moved over to SAMPLE.

The Model 325 is designed for ppmO2 analysis. If a system like this is of interest to you, contact Nova for details.

1-800-295-3771

sales at nova-gas dot com

websales at nova-gas dot com

http://www.nova-gas.com/

https://twitter.com/NOVAGAS

http://www.linkedin.com/company/nova-analytical-systems-inc-

http://www.tenovagroup.com/

#163 - Explosion Atmosphere Analysis Application

The recent mining deaths in Colorado USA involved two miners who died of carbon monoxide poisoning after they entered an area of the mine where an explosive had previously been detonated. (link)

We usually think only of the dynamic physical effects caused by explosions. However, explosions can also create gas emissions that have some resemblance to combustion atmospheres.

A couple years ago, we were approached by Queen’s University located in Kingston, Ontario, Canada to assist with atmosphere analysis in mining research.

They were detonating an explosive charge in a chamber approximately 14m3 (500ft3). The produced atmosphere was pumped to a monitoring station about 10-20m away.

The atmosphere developed in the chamber was no doubt a product of the following constituents:

- the products of heat and combustion

- the prevailing atmosphere prior to the explosion; e.g. O2 content

- the chemistry of the explosive

The gas analysis required was:

0 – 25% O2

0 – 2,000ppm CO

0 – 20,000ppm CO2

0 – 800ppm NO2

0 – 800ppm NO

The CO / CO2 were done by infrared detectors. The other gases were done by electrochemical sensors.

It is understandable that an explosion event can be very dusty. In this case, the explosion atmosphere was contained inside a chamber and the intention was to analyze the gases soon after detonation. To enable this, a remote probe & heated filter was supplied. After the explosion, the probe / filter assembly would be mated to the chamber via a set of bolted flanges similar to the graphic below.

Another option would have been to permanently mount the probe onto the chamber and install a heavy manual valve in the pipe between them. After the explosion, the valve could be opened and analysis begun.

During or after analysis, a supply of instrument air or N2 could be connected to the filter assembly enable a blow-back function which sends a blast of high pressure air/N2 back through the probe and filter to push any accumulated dust back out into the chamber.

Connected to the filter system was the analyzer which had a built-in pump. The pump pulls a gas sample through the probe and filters and into the detectors for analysis. If the sample tubing between the chamber and the analyzer runs outdoors in cold weather, the tubing will require some form of freeze-protection. This will ensure that any condensation will not freeze up and block flow.

Besides the gases listed above, it was expected that up to 1000ppm NH3 would develop in the chamber. The analyzer was therefore designed with NH3-resistant components to prevent corrosion. Up to 5000ppm CH4 was also expected, but this was not a corrosion concern. We were able to propose a ppmCH4 detector. However, this did not end up being needed.

If a system like this is of interest to you, contact Nova for details.

1-800-295-3771

sales at nova-gas dot com

websales at nova-gas dot com

http://www.nova-gas.com/

https://twitter.com/NOVAGAS

http://www.linkedin.com/company/nova-analytical-systems-inc-

http://www.tenovagroup.com/

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#162 - Solar Field with Capability to Generate at Night

From the http://phys.org/ website:

http://phys.org/news/2013-10-arizona-solar-hours-sun.html

Interesting article about Abengoa's Solana solar plant in the desert near Gila Bend, Arizona. This facility covers 7.8 sq km / 3 sq miles, with the majority of the area taken up by rows of parabolic mirrors. The mirrors focus and concentrate sunlight onto a pipe that contains a heat transfer fluid. The heated fluid travels to boilers where the heat is exchanged with water, creating steam. The steam drives 140-megawatt turbines to produce electricity.

The heated fluid process is really is a thermal storage system that allows the plant to continue generating electricity at full output for approximately 6 hours even after the sun goes down. This addresses some of the intermittency issue, which is an often-cited disadvantage of solar power. The additional 6 hours of power generation allows the plant to meet the peak electricity demands of evening and early night-time.

Pictures © 2013 copyright Ed Gunther

http://guntherportfolio.com/2013/01/abengoa-solar-solana-generating-station-sortie/

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#161 - Debate over Burial of Radioactive Waste near Lake Huron

The town of Kincardine and some surrounding communities in Ontario Canada have provided their support to a proposal to bury radioactive waste in an area near Lake Huron.

The waste is classified as "low-level" and is comprised of ashes from incinerated mop heads, paper towels, floor sweepings, and other debris. It would also include "intermediate waste" such as discarded parts from the reactor core. Most of the waste would decay within 300 years, but some of the intermediate waste would stay radioactive for more than 100,000 years.

This Nov. 1, 2013 photo shows rows of chambers
holding intermediate-level radioactive waste in shallow pits
at the Bruce Power nuclear complex near Kincardine, Ontario.
(Caption from CTV News website - AP Photo/John Flesher)

According to the proposed scheme, the waste would be placed in impermeable chambers drilled into sturdy limestone 2,230 feet below the surface, topped with a shale layer more than 600 feet thick.

The strongest opposition to the scheme seems to be over the fact that the storage chambers are less than 1 mile (1.6km) from Lake Huron, a source of drinking water for many US and Canadian communities. The lake's maximum depth in the vicinity of the nuclear site is about 590 feet. Opponents have contended that seeping groundwater would fill the chamber in a short time, become contaminated, and eventually reach the lake through tiny cracks in the rock. However, the radioactive material in question has been stored above-ground since the late 1960's and needs a permanent resting place.

Many individuals and communities have a knee-jerk reaction to nuclear power which is sometimes based on misinformation. Existing energy sources such as the oil and coal industries no doubt have something to gain from suppressing the development of nuclear technology. However, not all aspects of nuclear energy production are as bad as many people perceive them to be.

See - 
http://nextbigfuture.com/2013/11/carnival-of-nuclear-energy-184.html
http://www.hiroshimasyndrome.com/radiation-the-no-safe-level-myth.html
http://www.hiroshimasyndrome.com/environmentalists-for-nuclear-energy.html

From the Chem.info website - http://www.chem.info/news/2013/11/nuclear-waste-burial-debate-rages-along-lake-huron#.UpihQ8RDvG5

Also: http://kitchener.ctvnews.ca/kincardine-residents-back-plan-to-bury-nuclear-waste-near-lake-huron-1.1561064#ixzz2m2dph3s3

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#160 - Improving the Safety of Hydrogen Analysis - Nova Model 436 for Generator Monitoring

Many large power generators use hydrogen gas as a coolant. Hydrogen has low density and very good thermal conductivity. It can carry away the heat produced in a generator and thus allow the generator to operate at a higher power output.

The Nova Model 436 is an excellent choice for continuous monitoring of the hydrogen atmosphere in a generator. It offers the following analysis ranges:

Range 1: 0-100% Hydrogen in Air

Range 2: 0-100% Hydrogen in CO2

Range 3: 0-100% Air in CO2

This model is similar to the portable Model 380 mentioned in this post. When a generator shutdown is scheduled, it is recommended that the continuous analyzer is used to monitor the purge process, while a portable analyzer is also connected and used as a back-up monitor.

We have been asked recently by some power companies to consider offering an additional interesting feature to the Nova Model 436.

In some cases, an unsafe condition has developed when the continuous H2 purity analyzer has been accidentally switched to the wrong range and left to operate that way. The analyzer will now be looking for an incorrect combination of gases and will not report a reliable result. Because H2 purity is an important parameter to monitor during normal generator operation, the analyzer should remain set to the correct range for reliable results.

Would this feature be of interest to you? 

To ensure that the purity range is activated at all times during normal generator operation, an explosion-proof lock-enabled switch can be provided. The purity range would be always locked on, and only a key could disable it and enable the purge ranges. The key would stay in the slot during purge, and only be removable when the purity range is selected again. Perhaps the key would be kept in the supervisor’s office when not in use.

If this is of interest to you, contact Nova for details.

1-800-295-3771

sales at nova-gas dot com

websales at nova-gas dot com

http://www.nova-gas.com/

https://twitter.com/NOVAGAS

http://www.linkedin.com/company/nova-analytical-systems-inc-

http://www.tenovagroup.com/

#157 - Musk: "3 fires, with no serious injuries, received more headlines than 250,000+ gasoline fires"

Interesting article on the treehugger.com website with some decent perspective on the recent Tesla car fires.

http://www.treehugger.com/cars/elon-musk-3-model-s-fires-no-serious-injuries-or-deaths-received-more-national-headlines-all-250000-gasoline-fires-combined.html

We were talking about these cars in a recent blog post because we had one parked outside of our facility the other day.

Besides the many car fires, it seems like there is an accident, fire, or spill with petroleum products somewhere in the news every day. The extraction, refining, transport, and combustion of fossil fuels is without a doubt prone to incidents. How this record will compare to automotive battery technology in the future remains to be seen. But it is hard to imagine that the Tesla will seriously pose even a minor danger compared to the activities of big oil.

Elon Musk's comments in the title allude to that realistic comparison despite the media attention suggesting the opposite.

Oil fire picture - AP / Diario EL Amanecer from http://www.ctvnews.ca/world/deadly-venezuela-oil-refinery-blast-expected-to-impact-gas-prices-1.929521

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#156 - Nova Analyzers from the Field – Episode 2

We noticed this portable Nova analyzer on the equipment list of a metallurgical lab at the University of Laval in Quebec, Canada. It looks like this facility within the university is focused on aluminum production research.

The analyzer model is probably Nova 335L. The Model 335 analyzers usually use thermal conductivity technology to measure hydrogen in a binary gas mixture such as H2 in air or H2 in nitrogen. However, the 335L signifies ‘low range’ and refers to trace H2 measurement at ppm levels. The description on the University’s list indicates that the range of this particular unit is 0-2000ppm H2.

Nova’s low range H2 instruments use an electrochemical type sensor instead of a thermal-conductivity detector. A thermal-conductivity based analyzer does not have the sensitivity to measure gases in the ppm range. This is makes sense; we wouldn't expect a few ppm of a constituent gas to significantly change the overall thermal-conductivity of a gas mixture.

We can assume that the typical gas sample at Laval’s aluminum lab contains little or no O2. How do we know this?

From the photo, you will note that this analyzer has two flow meters and an air flow control adjustment on the front panel. One characteristic of many electrochemical sensors is that they require the presence of a small amount of oxygen to function properly. If a gas sample does not have at least a small amount of O2 in it, the signal output of the cell will begin to taper off as the diffusion layer at the sensor inlet is depleted of residual O2. To maintain a good electrochemical response to the target gas, a small amount of O2 needs to be metered in also. The flow control and the second flow meter are used for this purpose.

The Model 335L doesn’t appear to be visible on the Nova website. So if you have a requirement for analysis of ppm H2, contact us with your inquiry. We can help determine if the Nova Model 335L is suitable for your application.

Episode 1 - old portable flue gas with dual CO channel

For information on Nova gas analyzer systems, give Mike or Dave at Nova a call, or send us an e-mail.

1-800-295-3771

sales at nova-gas dot com

websales at nova-gas dot com

http://www.nova-gas.com/

https://twitter.com/NOVAGAS

http://www.linkedin.com/company/nova-analytical-systems-inc-

http://www.tenovagroup.com/

University of Laval website:

http://www2.ulaval.ca/en/home.html

Industrial Research Chair NSERC/Alcoa on Advanced Modeling of Electrolytic Cells and Energy Efficiency (MACE3)

http://www2.ulaval.ca/en/research/research-groups-and-chairs/research-and-innovation-chairs/industrial-research-chairs.html

Equipment List

http://mace3.fsg.ulaval.ca/en/recherche/equipements/

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#155 - Chem.info update on CO Poisoning in Colorado Mine

The Chem.info website quotes an Associated Press update on the incident involving the recent mining deaths in Colorado, USA. Two miners who died of carbon monoxide poisoning apparently entered an area of the mine where an explosive had been previously detonated, federal investigators said Monday.

Carbon monoxide (CO) is odorless, colorless, and toxic. In a mine it can come from combustion engines and explosives. It can accumulate in an area of a mine at high enough levels to cause injury and death.

Miners have air packs to supply them with oxygen during an emergency. However, it is not certain if the miners had any means of detecting elevated levels of carbon monoxide in that area of the mine.

No doubt the U.S. Mine Safety and Health Administration is continuing to investigate the unfortunate deaths.

Additional information on gas monitoring & analysis applications in mines:

http://nova-gas.blogspot.ca/2013/07/133-breathing-air-in-mine-shafts-part-1.html

http://nova-gas.blogspot.ca/2013/07/134-breathing-air-in-mine-shafts-part-2.html

http://nova-gas.blogspot.ca/2013/08/136-coal-mine-gas-analysis-applications.html

http://nova-gas.blogspot.ca/2013/08/139-coal-mine-gas-analysis-applications.html

Chem.info article:

http://www.chem.info/news/2013/11/update-co-mining-accident?et_cid=3608718&et_rid=43997774&type=headline#.UouvYsTWQtA

#152 - Tesla Parked at Nova Offices

We noticed a Tesla parked outside our offices recently. This was just a few days after news of a Tesla car fire was making the rounds in the USA.

The driver in the news story apparently ran over a trailer hitch and punctured the protective casing around the battery. The car’s dashboard display gave him a couple of text warnings. The driver’s comments were as follows:

About 30-45 seconds later, there was a warning on the dashboard display saying, 'Car needs service. Car may not restart.' I continued to drive, hoping to get home. About one minute later, the message on the dashboard display read, 'Please pull over safely. Car is shutting down.'

Shortly after the driver exited the car, the fire started. An CNet account of the incident can found here. 

This is apparently the third Tesla car fire. No doubt, some people will begin questioning the safety of this type of car. But it will be a long time before any direct co-relation can be made. Especially when U.S. fire departments respond to an estimated average of 152,300 automobile fires per year. Clearly there can be safety concerns with vehicles powered by combustible fuels such as gasoline and diesel. Because the Tesla is a new car bearing a newer concept, it will have to withstand scrutiny from critical audiences for some time.

However, the US National Highway Traffic Safety Administration gave the Tesla a 5-star safety rating. The driver mentioned above is convinced that the design of the Tesla may have saved him from serious injury. He says he would not hesitate to buy another Tesla.

http://www.nfpa.org/safety-information/for-consumers/vehicles

Car fire pic credit: tommolog/TeslaMotorsClub Screenshot by Chris Matyszczyk/CNET

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#150 - Testing Rare-Earth Element Extraction in Jamaica

During a post-holiday euphoria a couple years ago, I did a post on some of the analysis applications that we have had in the Caribbean areas. One such application involved the Noranda Bauxite Mine in St. Anne, Jamaica.

I just returned from another holiday in Jamaica and our trip to the resort took us past this facility once again. The driver of the coach explained that the mine itself is set back from the highway. The extracted ore is crushed and then conveyed to the large circular dome structure near the coast which stores and dries it. When a ship arrives at the docks in St. Anne, the crushed ore is transferred to the dock facilities by means of a conveyor system that extends under the highway and up into the ship loader. (see pictures)

The mine itself is not actually visible from the highway because of its higher elevation.
Jamaica is surprisingly mountainous and the mine is located up in these regions.
Coastal roads, towns, and many resorts are obviously located down closer to sea level.

Much of the Noranda bauxite is shipped to their alumina processing facility in Gramercy, Louisiana, USA. However, a recent initiative has emerged in Kingston Jamaica to test the feasibility of extracting rare-earth elements from the waste of the bauxite mine in St. Anne.

Jamaica's energy minister, Hon. Phillip Paulwell, has opened a pilot plant where researchers will conduct this testing. The work is in cooperation with Nippon Light Metal Co. Ltd. of Japan, which holds a patent for a type of technology that extracts rare-earth elements from red bauxite residue. Rare-earth elements are key ingredients for high-tech products like smartphones and computers.

Regarding mining and ore processing:

Tenova Takraf produces ore processing and handling equipment similar to what is installed at the Noranda site. Takraf has also been responsible for some of the largest port and ship-loading equipment ever built.

Tenova has also recently acquired Bateman with expertise in rare earth processing.

Aerial photo from Google Earth.
Jamaican rare-earth testing news from the Chem-info website.
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#147 - Hydrogen - Nova Model 380 for Generator Monitoring

Many large power generators use hydrogen gas as a coolant. Hydrogen has low density and very good thermal conductivity. It can carry away the heat produced in a generator and therefore allow the generator to operate at a higher power output.

The Nova Model 380 is an excellent choice for monitoring the hydrogen atmosphere in a generator. It offers the following analysis ranges: 

• Range 1: 0-100% Hydrogen in Air
• Range 2: 0-100% Hydrogen in CO2
• Range 3: 0-100% Air in CO2

The ranges mentioned above are designed to allow monitoring of the purge procedure that is implemented during a generator shutdown. However, not all purge procedures are exactly the same for each generator. We have been asked recently by some power companies to consider offering some additional capabilities to the Nova Model 380.

Would these features be of interest to you?

- We can produce a variation of Model 380 that allows it to be used on generators that are purged with Nitrogen (N2) instead of CO2.

- We can also produce a Model 380 that is set up for Argon (Ar) instead of CO2.

- We can also add dew point analysis and hydrogen pressure indication to Model 380.

If any of these options are of interest to you, contact us here about these options.

For information on Nova gas analyzer systems, give Mike or Dave at Nova a call, or send us an e-mail.

1-800-295-3771

sales at nova-gas dot com

websales at nova-gas dot com

http://www.nova-gas.com/

https://twitter.com/NOVAGAS

http://www.linkedin.com/company/nova-analytical-systems-inc-

http://www.tenovagroup.com/

_

#146 - Tenova Goodfellow Introduces Velocity Measurement for High Intensity Industrial Gas Streams

Tenova Goodfellow has developed a new gas velocity sensor that is able to continuously measure the velocity of a hot and dusty gas stream.

This system can accurately measure the velocity of gases that are in excess of 600 degrees C. Other methods of velocity measurement will not survive in such harsh environments.

We posted some additional information along with a brochure on the website. Check it out at: http://www.nova-gas.com/OVM%20-%20Landing%20page.html

#145 - Nova Analyzers from the Field – Episode 1

Intro - We frequently see old Nova equipment still in use all over the world. It’s amazing how long some pieces of sensitive analytical equipment can last in the right application. Every once in a while, I will try to post a picture and a short blurb about one of these older pieces that crosses our path. Here’s the first one:

We were sent a picture recently of an early model Nova portable analyzer. It is being used in a lab somewhere in Quebec, Canada by a company that manufactures furnaces.

This unit is approximately 27yrs old and is apparently still ticking.

The actual model number of this unit is no longer in circulation. And the serial number is so old that I couldn’t locate the original hand-written production file. However, some of the features of the front panel suggest that it is similar to our current Model 375.

The picture indicates that this instrument will do analysis of oxygen, carbon monoxide, carbon dioxide.

There is an illuminated push-button for ‘CO RANGE’ which probably allows the user to switch between a coarse and fine scale. The reason for this usually has to do with the operation of tuning a boiler or furnace. When the furnace is out of tune, it will produce higher amounts of carbon monoxide. Improving the fuel to air ratio will result in lower CO levels.

The high CO range on the analyzer will allow the technician to ‘see’ the CO analysis during the out-of-tune condition. After the coarse adjustments are made, the technician can switch to the fine CO scale for further tuning.

In the newer models, the ranges are as follows:

0-25.0% Oxygen

0-2000 PPM and 0-4.00% CO - switch selectable

0-20.0% CO2

Here is a link to the current model.

For information on Nova gas analyzer systems, give Mike or Dave at Nova a call, or send us an e-mail.

1-800-295-3771

sales at nova-gas dot com

websales at nova-gas dot com

http://www.nova-gas.com/

https://twitter.com/NOVAGAS

http://www.linkedin.com/company/nova-analytical-systems-inc-

http://www.tenovagroup.com/

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#144 - EnErgiron Direct Reduction Technology - Economical, Flexible, Environmentally Friendly

For more than 50 years, HYL (now Tenova HYL) has developed technologies designed to improve steelmaking competitiveness  and productivity for steel facilities. The HYL direct reduction (DR) technology, while perhaps the best known, is accompanied by other technologies designed for making steel in more efficient, cost-effective ways.

The HYL Process has been improved over generations and the current status of the technology, the HYL ZR (or Self-reforming) Process, was developed to allow reduction of iron ores in a shaft furnace without external gas reforming equipment. This process scheme has the ability to produce High Carbon DRI, which allows producers to obtain maximum benefits of carbon in the steel making process, while for merchant sale of the product, eliminating the need for costly briquetting equipment thanks to its highly improved stability.

The recent alliance between Tenova HYL, Techint and Danieli brings a new brand - ENERGIRON – to the forefront of the direct reduction industry. Current environmental regulations worldwide bring more stringent demands to the design of industrial plant operations of all types. 

Energiron technology is characterized by its flexible process configuration which is able to satisfy and exceed these requirements. In regions where either the high cost or low availability of natural gas work against this traditional energy source, the process is easily configured to operate using coke oven gas, syngas from coal gasifiers and other hydrocarbon sources. More importantly, the air and water effluents of the process are not only low but easily controlled.

Incorporation of selective carbon dioxide (CO2) removal systems has been a key factor over the past decade in reducing significantly the emissions levels, providing an additional source of revenue for the plant operator via the captured CO2. The high pressure operation and closed system of an Energiron plant combined with the HYTEMP Pneumatic Transport System reduces dust emissions to both air and settling tanks, making the process more economical and environmentally friendly.

DRI quality-High Carbon DRI

In the Energiron process, carbon in the DRI, mostly as iron carbide (Fe3C), is derived mainly from methane (CH4) and in less extent from carbon monoxide (CO). The level of carbon is adjusted by controlling the reducing gas composition and/or oxygen injection. Most of the carbon in DRI (more than 90% for carbon levels of 4%) currently being produced in the ZR scheme is in the form of iron carbide (Fe3C). The high percentage of Fe3C in the DRI makes the product very stable and presents a unique option related to storage, shipping and handling.

HYL is a member of the Tenova Group. HYL actively develops projects for direct reduction plants worldwide under the Energiron brand name. They started up the world's first successful direct reduction plant in 1957. Over 40 DR modules have been supplied worldwide since then.

http://www.tenovagroup.com/companies_hyl.php?id_company=2

For information on Nova gas analyzer systems, give Mike or Dave at Nova a call, or send us an e-mail.

1-800-295-3771

sales at nova-gas dot com

websales at nova-gas dot com

http://www.nova-gas.com/

https://twitter.com/NOVAGAS

http://www.linkedin.com/company/nova-analytical-systems-inc-

http://www.tenovagroup.com/

Photos copyright © 2012 HYL 

#143 - Steel Wheels of AIST

The Association for Iron & Steel Technology (AIST) is a non-profit organization with 16,000 members from more than 70 countries. Their mission is to advance the technical development, production, processing and application of iron and steel.

The board of directors is comprised of several industry leaders such as Francesco Memoli, Vice President Steelmaking, Tenova Core.

I noticed an excellent visual aid on their website recently called the Steel Wheel. It is a graphical representation of the steel-making process. Its circular format allows us to visualize how each of the subsequent steel-making processes are connected with the primary production of iron.

I think I will be putting this one in my ‘cool stuff’ file.

http://www.aist.org/resources/story-of-steel/chart-steel-making-process

For information on gas analyzer systems, give Mike or Dave at Nova a call, or send us an e-mail.

1-800-295-3771

sales at nova-gas dot com

websales at nova-gas dot com

http://www.nova-gas.com/

https://twitter.com/NOVAGAS

http://www.linkedin.com/company/nova-analytical-systems-inc-

http://www.tenovagroup.com/

#142 - Spare Parts and Service pages for Nova equipment

As an instrument manufacturer, we frequently get requests for spare parts and service. We recently added two buttons to the right hand side of our website to assist with those who require parts and service.

Each button leads to a form that is designed to facilitate these types of inquiries. The Submit button sends the inquiry into the Nova Parts & Service Departments who will respond in 1-2 days.

For information on gas analyzer systems, give Mike or Dave at Nova a call, or send us an e-mail.

1-800-295-3771

sales at nova-gas dot com

websales at nova-gas dot com

http://www.nova-gas.com/
https://twitter.com/NOVAGAS
http://www.linkedin.com/company/nova-analytical-systems-inc-
http://www.tenovagroup.com/

#140 - New Application Landing Pages on Nova website

A couple of years ago, we added some content pages to our website in an effort to provide more information on what industries we serve and what our equipment actually does. We already had a product catalog which showcased our products, but this was not the best venue to provide general descriptive information about our industry and company. These new content pages were called ‘landing pages’ by the people who assisted us with them.

The idea behind our landing pages is to provide an interval layer between the home page and the product pages. The landing pages can provide relevant information that is beyond the scope of the home page and that leads into relevant areas of a product catalog.

Our original landing pages represented a first attempt at bringing some organization to our very diverse product line and the many industries we serve. We did a couple pages that featured information on our products from a gas perspective, e.g. oxygen, carbon dioxide, etc. We also did a couple pages that were targeted to the industries we serve, e.g. landfill, power generation, etc.

Historically, we have noticed that our customers often have a general idea what they want, but they select the incorrect instrument for their needs. This is entirely understandable; we don’t expect people to know our product line in detail. We have some evidence that the landing pages were a frequent destination for our website visitors and were hopefully somewhat helpful as a transition into our product catalog.

However, we always felt that our original landing pages were a little light on detail. So we recently revised the content and added more pages. The intent is to provide our visitors with more relevant information and hopefully provide evidence that we have some analytical expertise.

We have done the following pages so far:

Steelmaking & Heavy Industry

Metal Heat Treating

Power Generation & Hydrogen Purity

Flue Gas & Emissions

Process Gas

Syngas & Gasification

Landfill & Biogas

Portable Landfill Analysis

Engine Exhaust

Ambient Air Quality

Analyzers for Hazardous Areas

Multi-gas Technology

The Model 380

Tenova Gas Velocity Measurement

What’s New on the Nova Blog

Nova Models Page

Tenova Goodfellow Page

Tenova Group Page

Oxygen Page

Carbon Monoxide Page

Carbon Dioxide Page

Methane Page

Hydrogen Page

Site Map Page

Check out whatever interests you.

As we think of more ideas, they will no doubt find their way onto a landing page on the website.

-

#139 - Coal Mine Gas Analysis Applications – Part 2

Last time, we talked about some gas analysis applications that emerged from a coal mine project in the southern USA. This mine is equipped with an elaborate tube system which allows air samples to be drawn from different parts of the mine to a central monitoring station.

The first instruments we provided to this facility performed beyond expectations. This enabled further cooperation between our companies on some additional projects. Here are the 3rd and 4th applications from this project.

Application #3 – Carbon Monoxide and Hydrogen Research

The next request from this facility was to expand the baseline air analysis. In detecting fire events in a distant part of the mine, it was suspected that there would be brief spikes of ppm CO and ppm H2 coming in through the relevant areas of the tube bundle.

Previously, measurement of these gases was accomplished using a Tedlar sample bag and an external laboratory located above ground. This process took several days to complete which effectively negated its value as a fire detection methodology. A continuous CO / H2 analyzer would provide an immediate measure of these gases without the inconveniences associated with the existing process.

The requested ranges were:

CO: 0 – 1,000 PPM

H2: 0 – 1,000 PPM

These gases and ranges are frequently achieved in analyzers using electrochemical sensors. However, these sensors have issues with mutual interferences. That is, CO provokes a response on the H2 sensor, and H2 provokes a response on the CO sensor. It would be impossible to obtain a reliable and accurate result where both gases were present in the sample at the same time.

The first and obvious approach was to switch the CO measurement methodology to IR (infrared). We have a long-path IR that is ppm CO capable. This method eliminated one of the interference problems. The IR reading will not be affected by the levels of H2 that were expected in the sample.

We do not have access to an alternate method for measuring ppm H2. However, we can utilize the stable output from the IR CO detector to provide some compensation to the H2 reading. This will subtract some of the CO effects from the displayed H2 result. However, it does not remove the physical effects of the CO on the H2 sensor. A spike of CO would provoke the expected response on the H2 sensor. The compensation circuit would help, but afterwards, the H2 sensor would be slow to recover.

So we devised a calibration procedure which allowed some ‘re-freshing’ of the H2 sensor to occur when needed. However, we noticed that the CO / H2 effects only seemed to occur during the spike periods. At the levels normally present in the mine, there did not appear to be any adverse affects on the continuous analysis. We assume that even if a spike occurred, the elevated readings would be valuable and the post-spike recovery could be managed as needed.

As with the previous applications, this analyzer required a reliable data-logging feature. We upgraded the data logger to a unit with larger capacity and a more convenient data storage process. The collected data is written directly to a SD card similar to what is used in many digital cameras. The SD cards are swapped out weekly for subsequent data analysis. We mounted the logger itself on the inside of the analyzer door. This protected it and allowed easy wiring access.

Data logger mounted on door of
gas analyzer and writes to SD memory card.

Application #4 – Air Flow Research

Very low levels of SF6 (sulfur hexafluoride) can be released in the mine as a tracer gas and tracked using the tube bundle. By ‘sniffing’ for SF6 in the relevant tubes, the air flow in the mine can be modeled. SF6 tends to have a persistent and detectable presence even after a long time and at very low levels. This allows the air flow model to be detailed and to capture subtleties not detectable by other means.

We have produced instruments for 0-100% SF6 for analysis of switch gear atmospheres. (Here is a link.) In large electrical switches where the possibility exists of dangerous arcing, a blanket atmosphere of SF6 will quench the arcs. To check the purity of the SF6 atmosphere, a gas analyzer can be used. The measurement methodology on these models is thermalconductivity.

However, the mine tracer gas application required a range of 0-50ppm. A percent scale instrument would not be useful in this case. The thermal conductivity detector does not have ppm SF6 capability. So we provided an infrared detector which can measure 0-50ppm SF6 in a background of breathable ambient air.

The same style of data logger was also integrated onto the door of the analyzer cabinet. Although it probably wasn’t necessary, we tested the output of this detector in background of air with spikes of H2 & CO as mentioned above in Application #3. No interferences or disruptions to the SF6 reading were observed.

Front view of continuous SF6 analyzer during
inspection phase. SF6 analysis on this instrument
done by infrared detector.

So far, all of the equipment we have supplied into this facility has worked well. The applications discussed in this post were somewhat experimental for us. But are occasionally willing to step outside of our standard designs for projects that interest us. With patience and support from the end-user in this case, we managed to produce instruments that will hopefully make a useful contribution to mine safety research.

For information on these and other gas analyzer systems, give Mike or Dave at Nova a call, or send us an e-mail.

1-800-295-3771

sales at nova-gas dot com

websales at nova-gas dot com

http://www.nova-gas.com/

https://twitter.com/NOVAGAS

http://www.linkedin.com/company/nova-analytical-systems-inc-

http://www.tenovagroup.com/

Switch gear picture - http://emadrlc.blogspot.ca/2012/07/alstom-145kv-gas-insulated-switchgear.html