In Situ Sensors for the Chemical Industry- Final Report (2006)

The project focused on analytical techniques that can be applied in situ. The innovative component of this project is the focus on achieving a significant breakthrough in two of the three primary Process Analytical (PA) fields. PA measurements can roughly be broken down into:Single component measurements, Multiple component measurements and Multiple component isomer analysis. This project targeted single component measurements and multiple component measurements with two basic technologies, and to move these measurements to the process, achieving many of the process control needs. During the project the following achievements were made: Development of a low cost Tunable Diode Laser (TDL) Analyzer system for measurement of 1) Oxygen in process and combustion applications, 2) part per million (ppm) H2O impurities in aggressive service, 3) ppm CO in large scale combustion systems. This product is now commercially available Development of a process pathlength enhanced (high sensitivity) Laser Based Analyzer for measurement of product impurities. This product is now commercially available. Development of signal processing methods to eliminate measurement errors in complex and changing backgrounds (critical to chemical industry measurements). This development is incorporated into 2 commercially available products. Development of signal processing methods to allow multi-component measurements in complex chemical streams. This development is incorporated into 2 commercially available products. Development of process interface designs to allow in-situ application of TDL technology in aggressive (corrosive, high temperature, high pressure) commonly found in chemical processes. This development is incorporated in the commercially available ASI TDL analyzer. Field proving of 3 laser-based analyzer systems in process control and combustion applications at Dow Chemical. Laser based analyzers have been available for >5yrs, however significant product price/performance issues have minimized their applicability in the chemical industry. In order to take advantage of the promise of this technology a number of technology advances were required, within price limits for market acceptance. This project significantly advanced the state of TDL technology for application in chemical industry applications. With these advances a commercially available product now exists that has already achieved market success and is installed in critical applications. The ability to make fast, sensitive and accurate measurements inside the chemical processes is now delivering improved process control, energy efficiency and emissions control within the U.S. Chemical Industry. Despite the success we enjoyed for the laser-based sensors, there were significant technical barriers for the solid-state sensors. With exception of a generic close-coupled extractive housing and electronics interface, there were significant issues with all of the solid-state sensor devices we sought to develop and test. Ultimately, these issues were roadblocks that prevented further development and testing. The fundamental limitations of available sensor materials that we identified, formulated and tested were overwhelming. This situation forced our team to cancel these portions of the project and focus our resources on laser-based sensor techniques. The barriers of material compatibility, sensitivity, speed of response, chemical interferences, etc. are surmountable in the field of solid-state sensors. Inability to address any single one of these attributes will prevent wide-implementation into this market. This situation is plainly evident by the lack of such devices in the online analyzer market (for petrochemicals).