#201 - Top 10 Nova Blog Posts from 2014

Probably everyone does a year-end post about what content was most popular on their blog. The areas of interest sometimes indicate an explainable trend, and sometimes they don’t. Nova is a technical company that manufactures analytical instruments. So our audience tends to be of the engineering and analytical types.

Our top 10 posts from 2014 are the following:

1. Post #167 - Using the Energiron Process with SynGas for DRI Production
2. Post #169 - Most Common Connections to Nova Analyzers (electrical & tubing)
3. Post #175 - Tenova Factories
4. Post #171 - New TGI White paper - Real-Time Water Detection in EAF Steelmaking
5. Post #173 - Nova tech climbs Mount Kilimanjaro
6. Post #168 - Nova Analyzers from the Field – Episode 4
7. Post #172 - Ash Classification Technology for Coal-fired Power Plants
8. Post #174 - Nova Analyzers from the Field – Episode 5
9. Post #178 - Nova Analyzers from the Field – Episode 6
10. Post #182 - Oil & Gas Spills Increase in 2013

For the most part, these posts from 2014 have simply accumulated higher popularity because they are from the first half of the year and are obviously older than any recent posts.

In terms of persistent interest, our ‘Analyzers from the Field’ posts seem to do well. People are always interested in reading about something ‘real world’. Frequently, these instruments have been in service for a number of years and have some kind of back-story that may be instructive.

Regarding Post #173 mentioned above, in May of 2014, one of our tech staff ventured to Africa to climb Mount Kilimanjaro. Lots of readers from inside and outside the Tenova Group were interested to hear the story and see the pictures. We still have tons of pics besides what we posted. We'll share a few more soon. 

Our all-time #1 post continues to be Post #70 - "Post #5 is our most popular blog post (Syngas and Gasification)". This one started out as a commentary on another popular post and then itself became most widely read. It indicates the continued interest in measuring the gas compositions produced by gasifiers.

Looking forward to 2015!

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

If you have any Nova instruments at your plant or lab and want to share a couple of photos, feel free to send them to us along with a brief explanation of your application.

1-800-295-3771

sales at nova-gas dot com

websales at nova-gas dot com

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

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#200 - Nova Analyzers from the Field - Episode 9 (Studies of CO2 Absorption / Desorption by Amine Solutions)

We were recently sent a published paper containing a brief mention of a Nova analyzer. The paper itself is about the kinetics of CO2 absorption in various aqueous amine solutions. We have periodically addressed this type of application over the years. As carbon dioxide (CO2) becomes more prominently connected with concerns about greenhouse gases, we expect to see more of it in the future also.

From the Introduction of the paper: 

“The separation of acid gas impurities such as carbon dioxide (CO2) and hydrogen sulfide (H2S) from gas mixtures is an important operation in natural gas processing, petroleum refining, coal gasification and ammonia manufacturing industries. Since CO2 is widely regarded as a major greenhouse gas, potentially contributing to global warming, recently, there has also been considerable interest in developing technologies for capturing and sequestering large quantities of CO2 produced from industrial sources such as fossil-fuel electric power generation facilities. Various technologies have been developed for CO2 and H2S removal from gas streams. These include absorption by chemical and physical solvents, cryogenic separation and membrane separation. Among these methods, gas absorption by chemical solvents such as aqueous solutions of alkanolamines is one of the most popular and effective methods.”

Even though this area of study has been active and applied in industry for over 50years, the authors note that complete investigations with mathematical models for absorption and desorption have been lacking. The authors then present a more unified approach in an effort to allow more standardized evaluations of this application across different reactions.

In this study, a novel design of laboratory contactor apparatus was used for interfacial contact between the amine and CO2. This apparatus allows for accurate and easier evaluation of physical mass transfer between the reactants. A diagram of the apparatus as presented in the paper is shown below.

The complete experimental setup from the paper is shown below:

After the dryer and just prior to the fume hood, the CO2 analyzer is shown in the above setup diagram. In this particular study the authors cite the Nova Model 300 infrared analyzer. In our experience, we have supplied a couple of different instruments for this type of application.

-          Model 302A – CO2 analysis by infrared detector

-          Model 336BT – CO2 analysis by thermal-conductivity (not shown in on-line catalog)

In one application in 2013, we supplied multiple units of Model 336BT in two ranges:

-          0-25.0 % CO2 in Air

-          0-100.0 % CO2 in Air

This application was for a large educational training assembly that involved the same absorption reactions between amine & CO2 mentioned above. The different instrument ranges corresponded to different points in the process before & after CO2 absorption. Purchasing separate instruments allowed simultaneous measurement of each point over a specific period of time.

In most cases, these studies are performed using portable instruments that provide accurate analysis on a temporary / intermittent basis. A wall-mounted version of this instrumentation can also be produced. For study apparatuses that are large enough to be permanently installed, a wall-mount analyzer in its own steel cabinet may be desired.

The study mentioned above is actually described in a two part paper as follows:

Part 1

Kinetics of carbon dioxide absorption and desorption in aqueous

alkanolamine solutions using a novel hemispherical contactor—I:

Experimental apparatus and mathematical modeling.

http://www.sciencedirect.com/science/article/pii/S0009250906003319

Part 2

Kinetics of carbon dioxide absorption and desorption in aqueous alkanolamine solutions using a novel hemispherical contactor—II: Experimental results and parameter estimation

http://www.sciencedirect.com/science/article/pii/S0009250906003381

Authors:

Aqil Jamal

Axel Meisen

C. Jim Lim

Department of Chemical and Biological Engineering,

The University of British Columbia

Vancouver, BC Canada V6T 1Z3

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/

Hey, this is Post #200 in our blog. Still haven’t run out of things to say!

Author: Aqil Jamal, Axel Meisen and C. Jim Lim

Publication: Chemical Engineering Science

Publisher: Elsevier

Date: October 2006

Copyright © 2006 Elsevier Ltd.

All rights reserved.
* Experiment diagrams and information property of authors

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#199 - Why Buy 970?

The most popular post on this blog is #70, which is ironically entitled “Post #5 is Our Most Popular Blog Post”. Post #70 was intended to highlight the previous successful post #5 that discussed the growing interest in our 970 Series analyzers for syngas applications.

These posts are probably so popular because there is much world-wide interest in gasification as an energy source. These posts contain specific information and pictures about gas analyzers that can successfully measure O2 / CO / CO2 / CH4 / H2 in produced syngas.

We are often asked questions about the price and configuration of the 970 Series. We do have instruments in our product line that are much smaller and simpler (as pictured below). There are other analyzer manufacturers in the marketplace that also have multi-gas capability like Nova, but who are possibly lower-cost. For a gasification application, is it simply a matter of obtaining an analyzer that will measure the gases of interest?

Not always. Gas analysis is usually only the second half of the whole task. The first half involves extracting the sample, filtering it, and drying it. Doing this properly in a syngas application is important.

There is an old saying about comparing ‘apples to apples’. When we are asked to compare the 970 to another analyzer that resembles the picture above, the first thing that we notice is that all of the sample extraction and conditioning components are missing. Unless the end-user is absolutely confident that the produced gas is clean and dry, this style of instrument will not function properly for very long. Trust us - we have learned that lesson the hard way in the past.

The Nova 970 Series Syngas and Gasification Analyzers are analytical instruments that are industrially hardened but user-friendly.

• High temp probe & heated filter at extraction point.
• Choice of compression or thermoelectric style moisture removal.
• Weather-proof cabinet with climate control.
• Stainless steel tubing and industrial components.
• Temperature-controlled detectors for O2 / CO / CO2 / CH4 / H2
• Accurate H2 measurement in varying background gases.
• High measurement ranges available; up to 100%.
• Built-in ‘Smart Control’ analyzer functions

Here is some more information plus a link to the 970 section of the catalog. 

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/

#197 - Borehole and soil gas analysis- Part 2

A while back, we posted some information about analysis of boreholes at decommissioned mine sites. Here is Part 1 of the discussion.

At the time, we mentioned that we have frequently sold the Model 309 Portable O2 / CO2 analyzer for this application. Because some of the samples will be pulled up from deep into the borehole, we can install a heavy duty pump into the instrument. This solution has been great for this application.

One mining company recently contacted us requesting a solution to a problem they were having with water accumulation in their analyzers. In the standard instrument we supply to this company, we incorporate a bowl filter of some kind at the sample inlet to capture any water that may come up with the gas. This approach has usually been adequate for the brief period that they have sampled at each point. However, at some boreholes, water accumulation in the interstices between the back-fill material and the liner has been significant. The analyzer has to pull out a large volume of water from each of the tubes in the bundle before the gas analysis can begin.

To cope with this reality, we proposed a closed catch-pot arrangement that isolates the water while maintaining the extractive suction. In operation, the sample pump pulls on the borehole tube. The entrained water comes up first and simply falls to the bottom of the clear bowl. When the water is evacuated from the tube, the gas sample passes into the detectors for measurement.

This arrangement is nothing new; it’s an old trick that has been around for years. We just haven’t implemented it in such an overt style with a portable analyzer. If you are monitoring soil gas from a tube bundle in a mine tailings borehole, let us know. We can offer a solution.

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/

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#196 - Nova Analyzers from the Field – Episode 8

Frequently, we get requests from power plants to offer a solution for hydrogen analysis. We mentioned before in this post and on the website here, that the power industry often uses hydrogen as a coolant for their electric generators. It is quite important in this application to maintain a high-purity of hydrogen. Reduction in purity can reduce cooling effectiveness and possibly allow an explosion potential to develop in the generator.

A common scenario involves older generators that still have the original hydrogen detector. The old H2 detector may be failing and a new instrument using modern technology and components is required.

Old GE Hydrogen panel.

We were sent these pictures from a large power provider in North America. The basic scope of this project was to replace the old OEM hydrogen purity analyzer which was manufactured by GE circa 1950’s. It measured the generator cooling gas, but in recent years, the spare parts and replacement sensors were getting too costly.

From the customer’s inspection of the old equipment, the old electronics consisted of wire wound resistors and transistors which had been obsolete for years. According to them, it was ‘state of the ark’ technology, as opposed to ‘state of the art’. The actual H2 purity measurement apparently used 100 ohm nickel RTD’s (resistance temperature detectors). Gas temperature and dew point of the gas are also usually measured in this application.

The upgrade project required a replacement hydrogen detector. The Nova Model 436 was the instrument of choice for this plant. This was probably because they had excellent success and performance from the portable 380 instrument that is used for the same application.

The generator has a fan on it to circulate the gas. One of the hurdles on this project was to get enough differential across the new analyzer sample cell to avoid having to vent the atmosphere gas out of the generator. They were able to configure the generator gas flow and sample input/output points to produce 0.6 LPM flow out of the generator, through the analyzer, and back into the generator.*

New Nova Hydrogen panel. Model 436N7N4 - The Control Cabinet
is on the left. The Detector Cabinet is on the right.

Recent performance evaluations at the plant indicate that the NOVA appears to have enough flow to measure correctly. The temperatures are measured with Rosemount Smart Temperature Transmitters. Everything seems to working very well now and they are very pleased with the results of their new panel.

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/

* Nova analyzers usually operate best with a flow of 1 LPM. However, in this case, the flow of 0.6 LPM will be sufficient as long as they calibrate at that flow rate.

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#195 - Mad Science follow-up

A few weeks ago, we had a post about some experimentation that we were doing with steel furnace rolling oil. The effort was focused on bringing a viable sample to a detector and obtaining a suitable response. That initial testing has recently translated into some real equipment.

Mini-furnace used for testing.

Two of the instruments built for this project.

Now that the instruments are built, we have been able to resume testing to verify the initial conclusions. Detector response is good as long as the sample temperature is maintained on the way to the analyzer port. This will require that the sample line be insulated and possibly even heated.

Internal layout. The detectors are
in the white heated box.

Sample input port. Most access ports on
Nova analyzers are located on the right
side of the cabinet.

The customer is commissioning the furnaces during this month and next. Altogether, 3 analyzer systems were built. The units provide a 3 channel analysis including LEL, O2, & DewPoint.

The whole challenge on this application was preserving the sample constituent intact to the detector. Our next project for research will probably be for a blast furnace gas analysis application. That application will no doubt focus on removing unwanted debris from the sample.

#194 - What is iBOF?

To begin, BOF is an acronym for Basic Oxygen Furnace. It is also a concept that is comprised of the furnace itself and an improved process for making steel from iron.

Excerpts from Wikipedia: 

"Basic oxygen steelmaking (BOS, BOP, BOF, and OSM), also known as Linz-Donawitz-Verfahren steelmaking or the oxygen converter process is a method of primary steelmaking in which carbon-rich molten pig iron is made into steel. Blowing oxygen through molten pig iron lowers the carbon content of the alloy and changes it into low-carbon steel. The process is known as basic because fluxes of burnt lime or dolomite, which are chemical bases, are added to promote the removal of impurities and protect the lining of the converter.

The process was developed in 1948 by Robert Durrer and commercialized in 1952–1953 by Austrian VOEST and ÖAMG. The LD converter, named after the Austrian towns Linz and Donawitz (a district of Leoben) is a refined version of the Bessemer converter where blowing of air is replaced with blowing oxygen. It reduced capital cost of the plants, time of smelting, and increased labor productivity. Between 1920 and 2000, labor requirements in the industry decreased by a factor of 1,000, from more than 3 worker-hours per tonne to just 0.003. The vast majority of steel manufactured in the world is produced using the basic oxygen furnace; in 2000, it accounted for 60% of global steel output. Modern furnaces will take a charge of iron of up to 350 tons and convert it into steel in less than 40 minutes, compared to 10–12 hours in an open hearth furnace."

There are ways to optimize this process to further improve yields and increase efficiency. This brings us to iBOF.

iBOF as a registered trademark is a modular technology developed and offered by Tenova Goodfellow Inc. It is available either as an integrated technology package or as independent standalone modules to meet each customer's specific needs. The acronym itself stands for Intelligent Basic Oxygen Furnace.

The iBOF concept consists of the following modules:

End-point Detection Technology: is based on the industry-proven EFSOP off-gas analysis, off-gas sensors to measure temperature, flow and pressure and BOF process control models designed to enable a "Blow & Tap" practice without additional cost and delays associated with Sub-Lance Technology.

Slop Detection Technology: uses lance vibration analysis with real-time alerts to give operators advance warning of the onset of a slop event (link & link) and a measurement of slop severity. The system is designed to provide direct feedback control of lance position and oxygen flow rate, for rapid mitigation of the effects of a slop.

Optimized Post-Combustion Technology: uses EFSOP off-gas analysis in combination with off-gas temperature, flow and pressure sensors and a dual-flow lance with independent control of primary and secondary oxygen to control oxygen flow-rate, penetration, and timing. The result is optimal post-combustion efficiency and increased scrap-melting capability with minimal refractory or lance wear.

Auto-tapping Technology: employs advanced image analysis together with process models to control tapping practice, in either an operator-assist mode or a fully automatic mode. The benefits of this technology are decreased tap time and variability, reduced slag carry-over, and improved operator safety.

For more information, contact:

Tenova Goodfellow Inc.

6711 Mississauga Road, Suite 200

Mississauga, ON

L5N 2W3 - Canada

Phone +1 905 567 3030

Fax +1 905 567 3899

goodfellow@ca.tenovagroup.com

EFSOP and iBOF are registered trademarks of Tenova Goodfellow Inc.

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