#96 - Pictures of Extreme Cold Weather Analyzer Package

Outside Nova facility after
Dec 27, 2012 snowfall.

Last night’s snow storm that hit the North-Eastern US / Toronto / Niagara regions reminds me of our ‘extreme cold weather package’.

 

Gas analyzers and many other scientific instruments usually do not like the cold. If a gas sample has condensable moisture in it, there is a possibility of ice build-up in the wetted sample train. The electronics, valves, and detectors all prefer to function at approximately room-temperature or slightly higher.

 

Periodically, we have had requests from companies who are operating outdoors in the cold northern areas of North America and Europe. To cope with this reality, we came up with our Cold Weather Package a few years ago. The package includes a durable outdoor cabinet with a windowed door, cabinet insulation, and internal heaters. We generally specify this design for outdoor temperatures as low as -20°C (-4°F). We recommend that the analyzer be sheltered from the wind and sun. This will help stabilize the cabinet temperature and reduce temperature swings.

 

Every once in a while, we have customers who want to operate in even colder temperatures. We meet these requests by installing our ‘Extreme Cold Weather Package’. This package also has an outdoor cabinet, insulation, and heaters. We just add more of everything. The cabinet door is modified to replace the large window with a smaller window and insulation. We generally specify this design for outdoor temperatures as low as -32°C (-25°F). However, we have seen some of these packages installed on sites as low as -40°C (-40°F). We’re not sure how well these units are working. For some reason, no one ever wants to go outside and check on them when it gets that cold!

 

One thing that is really important on cold sites is heat-traced tubing. The input sample line, vent line, and drain lines should all be heat-traced to prevent ice build-up. Obviously, ice build-up in the lines will cause low flow conditions and other problems.

 

Pictured below is a cold weather unit that we sent recently to a Canadian site in Terrebonne, Quebec.

 

'Extreme Cold Weather Package' protects analyzer
from cold outdoor temperatures.



Gas analyzer display is still visible with cold
weather cabinet modifications.

 

Cold weather operation brings challenges. No doubt about that. However, we can manage those challenges by adding heat and insulation to the design.

 

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/

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#95 - Multi-Point Conditioning Systems for Mass Spectroscopy in DRI Plants

One of the unique projects we have worked on this year has been the development of conditioning systems for mass spectrometers at steel plants. The specific application is DRI (Direct Reduced Iron) plants, where iron ore is directly reduced to iron without the typical processes involving blast furnaces, coke ovens, basic oxygen furnaces, and other support plants. The DRI product can be used in electric arc furnaces (EAF) as a flexible additive to provide additional control over the end product or where the price and availability of scrap metal requires it.



DRI plants are quite large. The DRI product is fed into
bins which are positioned to feed directly into electric arc furnaces.

Mass spectroscopy is used by some steel makers to obtain analysis of their process gases. The main advantage of this technique is that it is versatile in terms of analytical capability. Numerous types of gases may be measured by a mass spectrometer.

Two challenges in coupling mass spectroscopy and steel processes such as DRI are the location and condition of the gas samples. Steel plants are usually sprawling industrial complexes with distances to some sample points being more than 250m (820ft). The condition of the sample is frequently hot, dusty, and under high pressure. For best analysis, the sample should be left intact, while managing the unwanted conditions.

Our solution to this dilemma has been to establish a primary conditioning system and a secondary conditioning system.

Primary Conditioning System

The initial task is to extract the sample while regulating it to a manageable pressure. Next, the sample needs to be filtered to remove particulate while it is still near the process temperature. A probe, flange-mounted isolation valve, and heated filter will accomplish these tasks.

Most projects have multiple sample points throughout the plant that require analysis. A primary conditioning cabinet needs to be mounted at each sample point.

Each sample line running from the primary conditioning cabinets needs to be maintained at a temperature above the dew point of the sample.

Secondary Conditioning System

The various sample streams must be collected, finish filtered, and distributed to the mass spectrometer. The entire cabinet and each sample line running to the mass spectrometer must be heated & temperature controlled. Each sample stream must have individual flow control and be alarmed for Low Flow condition.

In many cases, the entire system must be suitable for hazardous rated areas. Some systems must have provision to have each sample stream shut off in the event of a shelter atmosphere alarm.

The system configuration we have developed is designed for 8 simultaneous sample streams. We can accommodate more streams by adding cabinets as needed. The highest number of streams we have worked on so far is 13.

 

CUSTOMER: Al Nasser Industrial Enterprises

PLANT LOCATION: Abu Dhabi, UAE

 

Cooperating with us is HYL, a partner of Nova’s in 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 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/

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#92 - Metamerism – Part 2

Last time, the topic of metamerism as related to the coatings industry was discussed. We don’t really have any issues with metamerism in manufacturing gas analyzers, but the whole idea reminded me of some challenges that we do face in the analysis of atmospheric gases.

Analytical Interference

Various methodologies lend themselves to analysis of different gases. Some methods are more or less specific than others, and there is usually no ‘magic bullet’ sensor/detector for any one gas.

Hydrogen – At Nova, we offer analysis of percent hydrogen by thermalconductivity detector. Hydrogen has a high degree of thermalconductivity, and this property can be used to measure it. However, other gases also have various degrees of thermalconductivity. The presence of several other gases in a mixture can interfere with the effectiveness of a thermalconductivity measurement. For hydrogen applications, we need to know what other gases are in the sample and the low/normal/high levels of each.

Methane & Hydrocarbons – At Nova, we offer infra-red analysis of hydrocarbons. The most common infrared analysis requested of us is methane. If the sample contains methane and enough other mixed hydrocarbons, some of the non-methane constituents will also produce a response on the infra-red detector. This is because many hydrocarbons have similar or overlapping IR spectra.

The methane reading may be compromised to an unknown degree by the non-methane hydrocarbons. For methane applications, we need to know what other gases are in the sample and the low/normal/high levels of each. We may be able to offer a methane-specific detector. In some cases, we may be able to compensate for the problem using certain calibration gas blends. Sometimes we can ignore the whole problem if the effects are not sufficient to be of concern to the end-user.

Electrochemical Sensors – At Nova, we offer analysis of various gases, including oxygen, using an electrochemical sensor. Electrochemical sensors are reactive by nature and are frequently affected by gases other the one of interest. For example, the gases carbon monoxide and hydrogen will often provoke a strong response on the same electrochemical detector. For electrochemical applications, we need to know what other gases are in the sample.

All of this really isn’t metamerism, but the ideas and potential consequences do bear some similarities. When discussing your analytical needs with Nova, we may request that you fill out an Application Questionnaire. This form is intended to assist you to provide us with critical data that may influence the type of equipment that is feasible in your application.

Nova Application Questionnaire
http://www.nova-gas.com/appq.html

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/

IR Spectrum:

NIST Chemistry WebBook (http://webbook.nist.gov/chemistry); COBLENTZ SOCIETY; Collection (C) 2009 copyright by the U.S. Secretary of Commerce on behalf of the United States of America. All rights reserved.

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#91 - Part 2 of “Post #5 is our most popular blog post”

I mentioned recently that Post #70, which was called “Post #5 is our most popular blog post (Syngas and Gasification)”, has itself now become our most popular post. I guess if you say something is popular, that proclamation alone is enough to pique some interest.

Another reason for the popularity is probably because of its topic - syngas and gasification. Specifically, the analysis of syngas composition.

In this application, the critical gases are H2 and CO. However, most of our gasification customers want analysis O2 / CO / CO2 / CH4 / H2. We can offer this combination of gases in any range in a single analyzer.

Here’s one that we are building now to support a Fischer-Tropsch process in which H2 & CO are converted into hydrocarbons in the presence of a catalyst.







As a follow-up to Post #5 and Post #70, we have another update to offer on this topic:

Besides having a capable analyzer for this application, it is also important to condition the sample properly before analysis. 

 

Hot Extraction and Filtration

Depending on the feedstock being used in the gasifier, the sample may have a significant amount of particulate in it. It is important to remove the particulate before condensation develops and mixes with the particulate. A heated filter that is mounted behind the probe at the extraction point is a good solution. A version of this filter can even be produced for high pressure samples or for Class 1 Division 2 Hazardous Rated Areas.

 

 

 

Tars

 

Many of our customers have reported to us that if the feedstock is comprised of woodchips or other wood-based matter, there is a strong possibility of tar being in the sample gas. These tars may condense out onto various surfaces. Especially of concern are the optical surfaces of the detectors. We have had some success in removing tars by integrating a gas cooler in a separate cabinet beside the analyzer. This encourages the condensable tars to accumulate on a non-critical surface away from the detectors. Ideally, the cooling assembly should be somewhat modular to allow easy access for cleaning or replacement.

 

Theoretically, a chemical scrubber can also remove the tars. But some of the solvents that might be used, isopropyl alcohol for example, may be carried into the analyzer and provoke a response on the infrared detector. This can be interpreted and presented by the analyzer as a falsely high CH4 reading. So we have been cautious about IR analyses where these types of scrubbers are installed. If the scrubbing solvent is water-soluble, a possibility might be to integrate a water-wash system in front of the analyzer as discussed below. (We haven’t tried this solution yet in this context, but it is an interesting idea.)

 

 

Soluble Gas Removal

 

On some projects where the feedstock is municipal waste with high variability, we have noticed the presence of other gases besides just H2, CO, & hydrocarbons. For example, there may be SO2 or NH3 in the sample gas. These gases may be detrimental to the long-term operation of the analyzer, so it is frequently best to eliminate these gases from the sample. On some gasification projects, we have supplied water-wash systems to scrub out any corrosive gases that are water-soluble.

 

 

 

Multiple Gasifiers or Multiple Sample Points on a Gasifier System

 

Sometimes analysis of multiple points with one analyzer is required. We have supplied an industrially-hardened version of our auto-sequencer for some gasification projects. This system will continually pull a sample from several sample points and send only one at a time to a single analyzer. The auto-sequencer will cycle through the sample points according to a user-defined schedule. Generally, the dwell time on each sample is a few minutes.

 

 

 

 

 

 

 

 

 

 

Not sure if this post will become as popular as the other gasification-related posts. But we will try to continue providing updates on Nova solutions for this interesting application.

 

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/

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#90 - Metamerism – Part 1

“Metamerism” is primarily a chemistry term for a type of isomerism in which chemical compounds have the same molecular weight and identical proportions of the same elements, but have different chemical properties because of radicals of different types or in different positions. Sounds complicated, but it’s basically a reference to two chemicals that you would expect to behave the same, but don’t because of minor differences.

In the coatings industry, especially in pigmentary studies, metamerism has a somewhat different meaning, but the idea is still sort of the same. Metamerism is a term used for when two colored samples appear to match under one set of lighting and viewing conditions, but not under another set. Metameric dissimilarity may also be due to differences in observers’ color perception aside from lighting or viewing conditions.

There are instruments available that simulate
various lighting and viewing conditions to
help manage unexpected metameric effects.

I have noticed that metameric effects are often more pronounced in coating systems that do not have high opacity and where the substrate is colored (non-white), or where the system is comprised of multiple layers of varying color contribution. Coatings that incorporate different types of coloring material types also seem prone to metamerism (e.g. organic/inorganic colorants or dyes/universal colorants added post-manufacture).

An example scenario might be a manufactured article whose color is designed and agreed to under the viewing conditions at the manufacturing facility, but doesn’t match expectations when the article is completed and moved to the final location. Metamerism may be the reason. (I say ‘may be’ because a legitimate manufacturing error may also be the cause.) During my time in the coatings industry, I dealt with metamerism often enough to appreciate its potential for disruption.

At Nova, we are thankful that we do not have to worry about such aesthetic complexities in our manufacturing process. Making gas analyzers is complicated enough already. But there are a couple of phenomena in gas analysis that remind me a little of metamerism. I’ll talk about those next time.

The Nova blog appears to be about gas analyzers, and yet this post discussed a completely different subject. Literary metamerism.

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/

Pictures:

Copyright © INTEKE INSTRUMENT CO. LIMITED

http://www.inteke.com/

 

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#86 - New Nova Video on Youtube

Very low budget video made at Nova 'studios' and posted on YouTube.

http://www.youtube.com/watch?v=3uhQH9RcJ6U

It is a 3-min presentation intended to briefly show some of the value proposition inherent in Nova continuous gas analyzers.

NOVA Analytical Systems

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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#85 - Caribbean Applications

A couple of my holiday shots. The pictures shown below are of the Noranda Bauxite Mine in St. Anne, Jamaica.

The last time in Jamaica, I drove by this facility and wondered what it was. I subsequently learned that it is part of a bauxite mine facility. Apparently after tourism, bauxite mining and agriculture are Jamaica’s largest industries. Coincidentally, I recently had a telephone call from the Superintendent of this very facility.

 

Copyright © 2007 – 2009 Noranda Aluminum. All Rights Reserved.

 

They apparently have a few diesel engines operating in individual rooms in the plant. The engine exhaust is obviously vented outside of the building. However, if a leak should develop in the exhaust system, it may result in dangerous accumulations of gases inside the building.

 

For the safety of their staff, they wanted to monitor the following gases:

• Oxygen Deficiency: 0-25%, alarms will sound if the O2 levels drop to 19.5% or lower
• Carbon Monoxide: 0-200ppm
• Nitric Oxide: 0-100ppm
• Sulfur Dioxide: 0-20ppm

These ranges of analysis cover the safe breathing conditions and permissible exposure limits of these gases.

 

To start, they have 3 engine rooms and they want to have some kind of centralized monitoring system. An auto-sequencer will be a good choice here. It is mounted right beside the monitor. This device is basically a series of solenoid valves and pumps which are controlled to pull different samples from different zones in a timed sequence. This will allow one monitor to be used for all three areas.

Eventually, they hope to tie the monitor / sequencer in with a PLC or a data collection system of some kind. But for now, labeled LED lights on the auto-sequencer will show which area is being sampled. And the monitor will show if any alarms are engaged.

 

We sometimes may forget that some of the Caribbean islands have other sustaining industries besides tourism. These regions no doubt struggle with a delicate balance of having profitable industry while preserving the beautiful environments that attract so many travelers.

 

We are occasionally contacted by Caribbean engineers & professionals for emissions analyzers. For example, in Trinidad and Tobago, we have sold continuous and portable flue gas analyzers into the petrochemical and gas process industries there. Legislative initiatives are apparently also moving these islands toward reductions in automotive exhaust emissions. We have also had requests from Curacao for information on emissions analyzers. Cutting back emissions is a good idea anywhere. But in areas that depend so much on pristine environmental beauty, it would seem to be nothing short of mandatory.

 

Nova Analytical Systems

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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