LAMTEC Meß

- und Regeltechnik für Feuerungen GmbH & Co. KG 

# Ceramic Gas Sensors for Optimisation of Combustion Processes

Dr.

- Ing Frank HammerLAMTEC Meß

- und Regeltechnik für Feuerungen GmbH & Co. KG 

### Outline



## › Overview of LAMTEC



## › Sensor Technology



## › Manufacturing Technology



## › Combustion Optimisation



## › Application



## › Summary



## › ReferencesLAMTEC Meß

- und Regeltechnik für Feuerungen GmbH & Co. KG 

### Overview of LAMTEC

- Company P rofile



## › LAMTEC Sensors and Systems for Combustion Engineering ( LAMTEC Meß

- und Regeltechnik für Feuerungen GmbH & Co. KG) Wiesenstraße 6, 69190 Walldorf, Germany



## › Established: 1st Juli 1995 as MBO from ABB



## › Shareholders: Dipl.

- Ing. Hans

- Jürgen Altendorf, Dipl.

- Ing. Bernd Jülg , Dipl.

- Ing. Harald Weber, Olaf Winne



## › Subsidaries / Associated Companies:

• LAMTEC

- Leipzig GmbH & Co. KG, Germany (100%)

• LAMTEC EA Buchon EA Buchon South Korea ( 80%) Jan. 2006

• LAMTEC Poland

• LAMTEC SEA Ltd. Kuching Malaysia (2010)

• OOO LAMTEC Moscow (2012),

• Escube GmbH & Co. KG Stuttgart, Germany (100%)



## › Employees : 100 (2 trainees )



## › Turnover 2013: 14.3 Mio. €LAMTEC Meß

- und Regeltechnik für Feuerungen GmbH & Co. KG 

### Overview of LAMTEC

- Locations

Headquarter Walldorf LAMTEC EAST ASIA Ltd. Buchon
, South Korea

LAMTEC Leipzig Development of hard

- and software Manufacture of flame scanners LAMTEC Neu Anspach Development of electronicsLAMTEC Meß

- und Regeltechnik für Feuerungen GmbH & Co. KG 

### Overview of LAMTEC

- Products/ Applications

LAMTEC Products/Applications Customers

Electronic burner control system

Fuel

- /air ratio control IR/UV
Flame monitoring system Process and fault indicator system O 2 measurement devices Option: Detection of non
- burned CO/H 2

Boiler manufacturer Plant manufacturer Measurement device manufacturer Burner manufacturer Industry Applications: Power plant/waste combustion Chemical industry Industrial application Measuring

- and control technology Research facilities and developmentLAMTEC Meß

- und Regeltechnik für Feuerungen GmbH & Co. KG 

### Overview of LAMTEC

- Sales PartnerLAMTEC Meß

- und Regeltechnik für Feuerungen GmbH & Co. KG 

### Overview of LAMTEC

- Product R ange

Burner Control

Electronic Fuel

- /Air Ratio Control

Volume Flow Measurement

Flame Detection

O 2 

### Optimization

O 2 

### Measurement

CO/O 2 

### Monitoring

Process and Fault Indicator System 

# Product R angeLAMTEC Meß

- und Regeltechnik für Feuerungen GmbH & Co. KG 

### Sensor T echnology

– Non

- Nernst Principle Design of a CO measurement cell

Non

- Nernst Sensor Voltage cathode 

### Ad

. phase : Gas phase : 

### p O 2 

### = 21 % , p CO 

### = 1 % , ( Rest N 2 

### )

O 2 , ad 

### = 99 % , CO ad 

### = 1 % O 2 , ad 

### = 90 % , CO ad 

### = 10 %

U S 

### Solid Electrolysis



###      

⋅ R

=

A ad K ad

CO CO S 

### C C F T U

, , 

### ln 2LAMTEC Meß

- und Regeltechnik für Feuerungen GmbH & Co. KG 

### Sensor Technology

– The Sensor Voltage



## › Langmuir a dsorption isotherm

• monomolecular adsorption layer

• ads ./des

. in stationary state condition (SS)



## › U S 

### is a function the coverage of anode and cathode Θ A 

### , Θ K


### • K A 

### =K K 

### : identical reaction kinetics SS

- constants through identical reactions (T E 

### =T K 

### =T S 

### , one measurement element )

• ∆ g ad,A 

### ≈ ∆ g ad,K 

### : Comparison of Gibbs enthalpies through similar adsorbents / adsorbate binding strength ( identical basic materials of electrodes on three phase boundary
, alloy of two phase layer for modification of adsorption on the anode ) 

###                
Θ

⋅ Θ

− Θ

− ⋅ Θ + R ∆

− ∆ +        
Κ Κ

⋅ R

=
A K A K K ad A ad

K A S
S S 

### T g g F T U ) 1 ( ) 1 ( ln ln 2 , , ) R⋅ ∆



### ⋅       Θ

− Θ

⋅ = S ad

ad T g

CO 

### e K c ( 

### 1 1LAMTEC Meß

- und Regeltechnik für Feuerungen GmbH & Co. KG 

### Sensor Technology

– The CO Sensor

Characteristics of Sensor



## › planar



## › multi

- layer



## › miniaturised

Functions of Sensor



## › Solid electrolyte



## › Non

- Nernst principle



## › electrocatalytic electrode Carrier substrate 3 , 520

t = 0 , 6 Contact point Zirkonia Heating coil

Glass cover Electrode 1 Electrode 2LAMTEC Meß

- und Regeltechnik für Feuerungen GmbH & Co. KG 

### Manufacturing Technology

– Thick Film Technology

Screen process engineering:



## › flexible



## › cost

- efficient



## › reproducible



## › mass producible squegee Screen jump screen

tension

screen squegee angle pressed thick film

screen printing paste

carrier substrateLAMTEC Meß

- und Regeltechnik für Feuerungen GmbH & Co. KG 

### Manufacturing Technology

– Raw Materials

Sensor materials



### › Al2O3

- carrier substrate



### › YSZ

- functional ceramics



### › Pt

- heating coil



### › Pt cathode/Pt

- alloy anode



### › Special glass cover

Innovative aspects



### › laser technology



### › h ybrid layer technology



### › sub

- μ and nano
- powder



### › ceramic printing pastes Solution II

Solution III

Solution IV

printing Medium Solution V

paste

HO destilled 2

Solution I stir 400 U / min 25 °C

400 U / min 60 °C , 5 min

400 U / min 25 °C , 2 min

400 U / min 25 °C , 2 min

400 U / min 25 °C , 2 min

400 U / min 25 °C , 2 min

Cool down 500 U / min 65 °C , 45 min

100 Umin 25 °C , 60 min Solution V Binder I

Plasti

cisers

Disperging agents

Binder II

Defoamer Ceramic

powder Moisturi

zers

screen

printing Screen stir

stir

stir

stir

stir

stirLAMTEC Meß

- und Regeltechnik für Feuerungen GmbH & Co. KG 

### Manufacturing Technology

– Process Optimisation

Simplification of the production steps through



### › Co

- firing which is used in the multi

- layer process of the manufactured sensors A decrease in



### › Production steps



### › Production time



### › Tempering processes



### › Sintering time



### › E nergy costs



### › Manufacturing costs Production chains with integrated process controls

co

- firing Printing Electrode 1

Drying Printing Electrode 2 Check / Testing Drying

Printing heating oil

Drying Printing YSZ

- Ceramic

Presintering Paste preparation

Ventilation Portioning Positioning Screen / SMD moulding
Cleaning of substances Mechanism Positioning Carrier substrate
Cleaning of substances Degreasing Positioning

Activation Electrode 2 Preliminary test Hard machining

Final testing Check / Testing

Check / Testing

Check / Testing

Check / Testing Check / Testing

Check / Testing

Check / Testing Check / Testing

Check / Testing Check / Testing Check / Testing Check / TestingLAMTEC Meß

- und Regeltechnik für Feuerungen GmbH & Co. KG 

### Manufacturing Technology

– Sensor Optimisation

Thermal analysis



### › i nstationary heating performance



### › stationary temperature distribution



### › stationary voltage distribution 

###  o ptimal sensor geometry

Thermography measurement



### › comparison between theory and practice



### › calculation of the sensor temperature T S from the electrical operating data Rh 

###  o ptimal operating temperature

500 600 700 800 900

13 15 17 19 21 23 25 y = 0

. 7673 x 2 + 17

. 139 x + 76

. 959 R 2 = 0

. 997 c )

Heating resistor R n in ΩSensor temperature Tsin KLAMTEC Meß

- und Regeltechnik für Feuerungen GmbH & Co. KG 

### Application

– The Sensor System

Sensors / Housing



### › small (< 3W)



### › robust (> 3 Jahre)



### › temperature stability (< 200 ° C / 500 ° C )



### › cost efficient (< 15 € )



### › fast (< 1s) Elektronics ( exaple )



### › s upply unit 14

- 20 V



### › temperature control



### › signal processing



### › analogue outputs 0

- 10 V or 0/4

- 20mA



### › relay outputsLAMTEC Meß

- und Regeltechnik für Feuerungen GmbH & Co. KG 

### Application : Combustion Technology

Today: Combustion Systems



### › Fossil fuels

• Limited resources ( c oal
, g as , oil )



### › Pollutant emission

• CO
, NO x , CO 2 etc.



### › Danger : Global warming



### Monitoring and Control of Combustion Systems Tommorow : Fuel C ells



### › Chemical reacting agents

• Unlimited resources (H 2 + atmospheric oxygen )



### › Pollutant emission

• No



### › Potential for damage : H 2



### Safety Monitoring of fuel cells and hydrogen infrastructureLAMTEC Meß

- und Regeltechnik für Feuerungen GmbH & Co. KG 

### Application

– Combustion Characteristic

Pollutant makers



### › Traffic



### › Industry



### › Household a nd small

- sized burners Existing sensor systems



### › Automobile: λ probe



### › Industry : λ / flue

- gas probe



### › Small

- sized burners : not available !


### ⇒ Development of miniaturised CO

- Sensors for combustion optimisation CO CH

nm Ruß

0

. 1 0

. 2 0

. 4 0

. 6 0

. 8 1 2 4 6 8

1 , 91 1 , 30 1

. 03 1

. 005 Incomplete combustion Flue gas heat lossηRuß,CO,CHnmefficiencyEmission edgeCombustion fuelsLAMTEC Meß

- und Regeltechnik für Feuerungen GmbH & Co. KG 

### Application

– Combustion Regulation

Combustion Control increases



## › The operational range



## › reliability of operation



## › safety

Combustion Optimisation



## › increases the efficiency



## › lowers fuel consumption



## › Minimises pollution S 2 S

1 P r o c e s s o r

Air Fuel Burner Flue gas channel Exhaust air Probe Electronic control

Combustion chamberLAMTEC Meß

- und Regeltechnik für Feuerungen GmbH & Co. KG Sensor element Status: series
Function tested in oil, gas and solid fuel firings since 1999 Production more than 20.000 pieces since 2002 Reproducibility Heater side Sensor side 9 ± 1 Ω , requirements are fulfilled requirements are fulfilled for combustion optimisation Field tests no blackouts of the sensor element since March 2002 Life time tests tests in oil and gas since Mai 2003, two peripheral blackouts, tests go on Price now: 250 € per piece; goal: 5

- 10 € per 100.000 piece 

### Summary

– State of the ArtLAMTEC Meß

- und Regeltechnik für Feuerungen GmbH & Co. KG Housing : Status: „ series “
Function around 2000 housings in operation (three different types) Production Integration standard high temp

. experiences with series: without problems up to 200 ° C, condensing atmospheres up to 450 ° C, condensing atmospheres

Life time tests tests in gas and oil since Mai 2003, two blackouts, problems solved, tests go on Price now: 250 € per piece; goal 3

- 6 € per 100.000 pieces 

### Summary

– State of the ArtLAMTEC Meß

- und Regeltechnik für Feuerungen GmbH & Co. KG Electronics Status: series
Function around 1000 units in operation since Mai 2003 Development Feb. 2003: prototype Mai 2003: pre
- series Oct. 2003: redesign pre

- series March 2004: zero series Life time tests no blackout since Oct. 2003 Price 500 € per piece 

### Summary

– State of the ArtLAMTEC Meß

- und Regeltechnik für Feuerungen GmbH & Co. KG 

### Summary

– State of the Art

Field tests ( excerpt ) electronics Status: „ pre - series with demonstrator

Burner Boiler Testing site Testing time Oil
, blue flame Buderus LAMTEC/ Odenheim since Sept. 2002 Oil
, blue flame Viessmann VITO/ Belgium Jan.

- Feb. 2002 Oil
, blue flame Rotex HLK/Stuttgart Jan. 2003 Gas, atmospheric Senertec VITO/ Belgium Jan.

- Feb. 2002 Gas, atmospheric Klöckner LAMTEC/Walldorf since Dec.1999 Gas, condensing Bosch Junkers HLK/Stuttgart Feb. 2003 Gas, condensing Buderus LAMTEC/Reisen since Aug. 2002 Gas, condensing Buderus LAMTEC/ Östringen March 2004 Bio mass Hoval CSEM/ Switzerland Feb.

- March 2001 Bio mass Brunner FH Karlsruhe/ KarlsruheSept . 2003LAMTEC Meß

- und Regeltechnik für Feuerungen GmbH & Co. KG 

### References

– Long Term Measurement Endurance test over 11 months



## › identical characteristics



## › no identifiable deterioration



## › sensitivity increases slightlyLAMTEC Meß

- und Regeltechnik für Feuerungen GmbH & Co. KG 

### References

– Sensors in Application (1) Front view of a dual boiler 50

- 1.000kW



## › 16 CarboSen1000 sensors were tested:

• in condensing flue gas Tmax = 80 ° C 100% condensation !

• directly in the combustion chamber Tmax = 600 ° !! No condensation ! SturzbrennerLAMTEC Meß

- und Regeltechnik für Feuerungen GmbH & Co. KG 

### References

– Sensors in Application (3) Mounting position in the condensing flue gas channel



## › 4 CarboSen1000, plugged in



## › 4 CarboSen1000, hanging



## › 1 Lambda probe, plugged inLAMTEC Meß

- und Regeltechnik für Feuerungen GmbH & Co. KG 

### References

– Sensors in Application (4) Mounting position in the hot incinerator



## › 1 CarboSen1000 immersion probeLAMTEC Meß

- und Regeltechnik für Feuerungen GmbH & Co. KG 

# CarboSen

27LAMTEC Meß

- und Regeltechnik für Feuerungen GmbH & Co. KG 

### CarboSen Miniaturised Sensor for Detection of Non

- burned (CO/H 2 

### ) in Combustion Exhaust Gas

28LAMTEC Meß

- und Regeltechnik für Feuerungen GmbH & Co. KG 

### CarboSen

29LAMTEC Meß

- und Regeltechnik für Feuerungen GmbH & Co. KG 

### Measurement Principal of CarboSen1.000

30LAMTEC Meß

- und Regeltechnik für Feuerungen GmbH & Co. KG 

### CarboSen Sensor Assembling



## › 11 layers incl

. carrier



## › Measure : 20mm x 3,5mm x 0,7mm



## › Material: ceramics , glas
, platinum
, gold

• Thermally and chemical robust



## › Production in thick and thin film process

• Cost

- effective
, suitable for mass market

31LAMTEC Meß

- und Regeltechnik für Feuerungen GmbH & Co. KG 

### CarboSen Characteristic

0 20 40 60 80 100 120 140

3000 3010 3020 3030 3040 3050 3060 3070 3080 3090 3100 Zeit in sUsen in mV

0 50 100 150 200 250 300 350 400 450 500CO referenz in ppm U Sen 01 in mV U Sen 02 in mV U Sen 03 in mV CO MRU in ppm

32LAMTEC Meß

- und Regeltechnik für Feuerungen GmbH & Co. KG 

### Test Plant of Oil

- Blue Burner

Qualification or reference measurement in pipe of oil

- blue burner 4 CarboSen1.000 in flue gas pipe Reference S ystem (KS1D)

33LAMTEC Meß

- und Regeltechnik für Feuerungen GmbH & Co. KG 

### CarboSen1.000ST

34 Characteristics :



## › Measurement of CO e directly in humid flue gas up to 150 ° C, also condensing 

## › No reference air necessary 

## › Protection class IP67 Applications :



## › Natural gas, fuel oil ELLAMTEC Meß

- und Regeltechnik für Feuerungen GmbH & Co. KG 

### CarboSen1.000

35 Characteristics :



## › Measurement of CO e directly in humid flue gas up to 400 ° C 

## › Elektronic is integrated in sensor head 

## › No reference air necessary 

## › Protection class IP67 Applications :



## › Natural gas
, fuel oil EL, p ellet, piece woodLAMTEC Meß

- und Regeltechnik für Feuerungen GmbH & Co. KG 

# Thank you for your attention

Questions?LAMTEC Meß

- und Regeltechnik für Feuerungen GmbH & Co. KG 

# Contact :

Steven Craig

– President, Hays Cleveland Phone: (216) 398

- 4414 Fax : (216) 398

- 8558 E

- Mail: scraig@unicontrolinc.com