PGC5000 Series Process Gas Chromatographs

Transcription

1 PGC5000 Series Process Gas Chromatographs Designed for Reliability and Simplicity PGC5000A Master Controller PGC5000B Smart Oven ABB Inc. Process Analytics 843 N. Jefferson Street Lewisburg, WV, USA Visit

2 Chromatography So Easy Everything You Need At Your Finger Tips! PGC5000A Master Controller Fully functional keypad and mouse touch pad 100 times traditional processing power Intrinsically safe fiber optic connections to Smart Ovens PGC5000B Smart Oven Simple configurations for maximum reliability Easy access to all major components The New PGC5000 Series Reliable Chromatography Made Easy. The PGC5000A Master Controller with new Graphical Driven HMI offers a fully functional keypad and touch pad mouse. Developing, editing and storing analysis methods are now easy. Function block programming is now a thing of the past. Just point and click and drag and drop are all that is required to access and change functions All major analyzer functions are identified on tabs making it easy to access any information. The PGC 5000B Smart Oven is designed for simple applications or making complex applications simple. Smart Ovens are optimized for advanced electronic pressure control; dedicated oven controllers locally execute analytical methods required for the stream's analysis. Multiple Smart Ovens break complex applications into individual sequences producing simpler, more reliable analyzers that are easier to understand and maintain. Flexible, scalable, simple and accessible. ABB Process Analytics Providing gas chromatographs to the Hydrocarbon Processing Industries for over 50 years. For more information, visit or contact AnalyzeIT@us.abb.com. Copyright 2008 ABB Power and productivity for a better world

3 Process Photometers PUV3402 and PIR3502 Applications, Technology and Data Continuous Measurements VistaNET Connectivity Multiple Component Samples Measures Vapor or Liquid Samples Operates in IR, NIR, UV and VIS Regions Fiber Optic Option for NIR Applications Multiple Interference Compensation Capability Analyze IT Field IT Control IT Engineer IT Field IT Inform IT Operate IT Power IT Industrial IT

4 Principle of Operation The PUV3402 and PIR3502 Process Photometers optical path consists of an IR or UV source, a brushless chopper motor, a multichannel filter wheel, lenses, cell with windows, and a solid state IR or UV detector. (See Optical Bench Schematic). L4 Sample Cell L3 L2 L1 The brushless chopper motor rotates the multichannel filter wheel reference and measure filters, alternately and continuously, into and out of the optical path. The lenses, L1 through L4, focus and collimate the source radiation through the sample cell path to the detector. On a multichannel photometer, a reference wavelength is chosen where the stream components have little or no absorbance. The measure wavelength or wavelengths are chosen where the measured components have absorbance. The microprocessor will then use matrix algebra and apply the proper response factor to each filter to eliminate interferences on the desired component and convert the absorbance to a component concentration. Detector Chopper Motor Filter Optical Schematic Advantages of the Design The PUV3402 and PIR3502 Process Photometers use a fixed wavelength filter, single beam, multichannel principle. This design concept offers several advantages: Produces a simple mechanical design that promotes easier service and maintenance. Compensates for obstruction of cell windows. Compensates for source and detector aging. Permits the sample cell to be isolated from the electronics. Enable multicomponent analysis. As illustrated by the Optical Schematic, the simple mechanical design has a single optical path, from the source directly to the detector. The source energy is focused and collimated straight to the detector. It does not require optical mirrors or internal reflections. Source Multiwave TM Process Photometer

5 This enables hardware components to be configured for self-alignment, making all components in the system easy to remove and replace. It also ensures a more reliable and stable long term performance. The cell windows can be obscured by up to 50 % without affecting measurement accuracy, because the single cell, multichannel design measures the ratio of the transmitted energy between the reference and measure wavelengths. Problems normally associated with dual chamber detectors and cells such as gas leaks, optical alignments, vibrations, pitting and corrosion of cell walls, are eliminated by the single beam multichannel design. Also, aging problems typically associated with two sources or two detectors are eliminated. Again, this design concept enhances long term stability and reliability. General Applications ABB PUV3402 and PIR3502 Process Photometers provide on-line measurements of gas or liquid components, in simple or complex process streams for: Process Efficiency Catalyst Protection Product Quality Environmental Concerns Safety Process Control ABB Process Photometers provide reliable performance in the Petrochemical, Chemical, Refining, Gas Processing and Product Pipeline industries. The ABB Process Photometer s single source, single detector design also enables the use of an isolated sample cell. An isolated sample cell has many advantages for on-line process measurements. Contact between flammable or corrosive streams and system electronics is prevented. Access to sample lines is made easier, and cell removal is simplified. Finally, this multichannel evolution of the fixed filter photometer allows measurements in streams where there are several interfering compounds; and it has the ability to measure multiple components in many applications. Left Side: Detector Right Side: Source

6 Spectral Range and Regions Spectral Range: Gas and Liquids with absorbance in the 0.2 to 15 micrometer region of the electromagnetic spectrum. Spectral Regions: Ultraviolet and Visible Near Infrared (Overtone Region) Fundamental Infrared (Rotation-Vibration) Fingerprint Region 200 to 800 nm nm 2.5 to 15 um 8.0 to 15 um The fingerprint region from 8 15 um is very useful because there is a high level of specificity in this region. ABB Process Photometer Field-Proven Applications The following chart is a partial listing of fieldproven applications. These applications are grouped by process. Measured components and key benefits are indexed for each application. Temperature and Pressure Ranges Temperature Ranges: Ambient Sample Cell Operating Temperature Pressure Range: Sample Cell 32 to 113 F (0 45 C) 32 to 392 F (0 200 C) 5 to 500 PSIG ( BAR) standard* *Higher pressures available upon request consult manufacturer.

7 Field-Proven PUV3402 and PIR3502 Process Photometer Applications Process Measurement Benefits Acid Gas Scrubbers Sodium Hydroxide 0 15 % Improved scrubber efficiency and reduced cost Acetic Acid CO % in Reactor Feed Maximize process yield Water 0 20 % in Reactor Outlet Distillation Tower control Water 0 10 % in Drying Column Inlet 2nd half of Distillation Tower control and determining expected life of Drying Column Water ppm in Drying Column Outlet Drying Column efficiency *Methyl Iodide ppm Scrubber efficiency and safety Ammonia CO ppm Catalyst Protection CH % Safety NH % Safety Area Monitoring Ethyl Benzene ppm, Safety, Leak Detection Styrene ppm, Isooctane ppm, Divinylbenzene ppm Crude Unit ASTM color 0 8 Product quality Ethylene Acetylene 0 2 % Hydrogenation reactor inlet continuous control Acetylene % Hydrogenation reactor mid-bed continuous control Ethylene Dichloride CO 0 10 %, CO2 0 5%, Process efficiency and safety and Ethylene 0 5 % *Chlorine ppm in EDC Process efficiency with Sparger System Ethylene Glycol *Percent Transmittance at On-line quality control of Ethylene 4 discrete UV wavelengths Glycol purity Maleic Anhydride CO %, CO %, Reactor Outlet Butane %, and Process Efficiency Maleic Anhydride 0 2 % Butane 0 2 % and Reactor Inlet Water Vapor 0 5 % LEL Control Phosgene CO 0 10 % Process Control *Chlorine ppm Process Control Phosgene ppm Safety Product Pipeline CO ppm Prevent freezing of natural gas Lines Sulfur Recovery H2S %, CO %, Acid Gas Feed Water 0 30 %, THC 0 10 % Forward Control H2S %, NH %, Sour Gas Feed Water 0 30 %, THC 0 10 % Forward Control Vinyl Chloride Water 0 50 ppm in EDC Catalyst protection, corrosion protection of reactors * = UV Application Vinyl chloride ppm, 0 2 % in HCl Condenser efficiency

8 Field-Proven Multicomponent Applications Multicomponent Measurements % toluene; 0 2 % tetrahydrofuran and % LEL of gas mix (3 components) 0 20 % CO; 0 20 % CO2; and 0 5 % CH4 (3 components) 0 55 % propane and 0 20 % propylene (2 components) ppm CH4 and ppm ethane in 100 psig (2 components) ppm CO and ppm CO2 in 200 psig (2 components) ppm fluorobenzene; ppm chlorine; and ppm SO2 in carbon bed vent gas (3 components) 0 5% CO2; 0 5 % CO; 0 1 % toluene and 0 1 % benzene in air oxidation vent (4 components) 0 50 ppm acrylonitrile and 0 50 ppm styrene in air (2 components) 0 50 ppm ethylene oxide and 0 50 ppm propylene oxide in air (2 components) 0 70 % methyl chloride and % methylene chloride (2 components) ppm SO2; ppm NO; ppm NO2 and ppm NOx (4 components) ppm ethane; ppm ethylene and 0 80 % methane (3 components) 0 40% CO2; 0 40 % CO and 0 25 % water vapor in air (3 components) 0 80 % ethylene and 0 15 % CO2 in mixed HC stream as a vapor (2 components) % CO; 0 60 % ethylene; 0 20 % CO2; and 0 5 % ethyl 70 psig (4 components) ppm water and 0 5 % DMSO in monochlorobenzene (2 components) % ethylene; 0 10 % EDC; 0 50 % HCl; and 0 20 % ethyl chloride (4 components) 0 20 % propadiene; 0 40 % methyl acetylene and 0 60 % MAPD (3 components) Water Measurements 0 2% water in phenol ppm water in monochlorobenzene 0 50 ppm water in ethylene dichloride ppm water in 75psig (vapor) % water in ethylene diamine ppm water in vinylidene chloride ppm water in propylene glycol ppm water in methyl ethyl ketone (MEK) ppm water in dimethylacetamide ppm water in allyl chloride % water in acetone ppm water in methanol ppm water in benzene ppm water in toluene diamine ppm water in MEK & alcohols

9 Field-Proven Applications Various Single Component Measurements 1,3 butadiene 0 50 %; in isobutene 1,3 butadiene 0 70 % acetic acid 0 2 %; in acetic anhydride acetylene 0 1 %; in methane; ethane and ethylene acetylene % ammonia ppm; in air cis-2-butene 0 10 %; in butadiene CO2 0 1%; in CH4 and C2H6 CO2 0 1%; in ethane CO ppm; in ethane CO ppm; in propane cyclohexane 0 30 %; in cyclohexanol cyclohexanone ppm; in cyclohexane ethane 0 10 %; in methane and propane ethylene 0 2 %; in ethane H2S 0 15 %; in sour fuel gas hexamethylene imine ppm hydrogen cyanide 0 1 % MEOH 0 20 %; in MTBE/TAME methane 0 6%; in H2 and water vapor methanol 0 40 %; in MTBE methyl bromide ppm in air propane 0 6%; in propylene propylene % total hydrocarbons 0 10 %; in propylene total hydrocarbons ppm; as butene-1 vinyl acetate 0 10 %; in ethylene vinyl acetate 0 20 %; in ethylene UV Field-Proven Applications APHA color 0 50 ASTM color 0 8 ASTM units benzene ppm; in water Bisphenol A 0 25 ppm and ppm; in water chlorine 0 30 %; in propane chlorine 0 10 %; in NaOH+H20 chlorine 0 2 %; in HCl chlorine ppm; SO ppm; in vent gas (2 components) chlorine 0 30 %; in propylene dimethyl aniline ppm; in N2 saturated with water DMAC ppm; in water H2S 0 10 %; in H2 H2S 0 4 %; in N2 Saybolt color -30 to +15 SO ppm SO ppm; in stack gas styrene 0 20 ppm; butadiene in water total aminobenzenes as aniline 0 50 ppm total phenols as 2-chlorophenol 0 25 ppm; in 33 % HCl in H20

10 Partial List of IR and UV Absorbing Compounds The following lists are provided as a general reference for determining potential IR and UV applications. Other considerations will be the remaining stream matrix, stream temperature, stream pressure, and stream phase. The sample must be homogeneous, single phase in order to apply the method. Please provide the needed information on your application to our customer service group so that application engineers can determine the feasibility of your application. Partial List of IR Absorbing Compounds (Potential Measurements) Butadiene (1,3) Butane (n) Carbon dioxide Carbon monoxide Carbon tetrachloride Chloroform Cyanogen Cyclopropane Diazomethane Dichloroethane (1,1 and 1,2) Dichloromethane Dimethyl amine Dimethyl ether Dimethyl hydrazine Ethane Ethyl alcohol Ethyl chloride Freon-13B Freon-14 Freon-C-318 Hydrazine Hydrogen bromide Hydrogen chloride Hydrogen cyanide Hydrogen sulfide Isobutane Methane Methyl alcohol Methyl azide Methyl chloride Methyl mercaptan Nitric Acid Nitric oxide Nitroethane Nitrogen dioxide Nitrogen pentoxide Nitromethane Nitropropane (1 & 2) Nitrosyl chloride Nitrous Oxide Phosgene Propane Propylene Trimethylhydrazine Trimethylamine Vinyl chloride Water Partial List of UV Absorbing Compounds (Potential Measurements) Acetic acid Acetone Ammonia Aniline Anthracene Benzene Bromine Carbon disulfide Carbon tetrachloride Chlorine Chlorine dioxide Chlorophenol (o,m,p) Dioxane Ethylbenzene Ferric chloride Fluorine Furfural Hydrogen peroxide Hydrogen sulfide Iodine Mercury Methyl mercaptan Naphthalene Nickel carbonyl Nitrobenzene Ozone Perchloroethane Phenol Phosgene Pyridine Sodium sulfide Styrene Sulfur Sulfur dioxide Toluene Xylene (o, m, p)

11 Enhanced Applications Capability To enhance the application capability of the Multiwave Photometer, six options are available. Optical Span Filter Temperature and Pressure Compensation Gas Samples Temperature Compensation is available on analyzers that do not have cell heat. It is intended to be used for vapor applications. There are two types of temperature compensation available: Gas Law Compensation Temperature Compensation is based upon the Ideal Gas Law and requires no calibration or set up. An example of where Gas Law Compensation may be useful is for streams at ambient temperature. Empirical Compensation Temperature Compensation is based on experimental data. It requires calibration in the factory lab. Pressure Compensation is used on vapor applications only. It is recommended on suppressed range applications such as % Chlorine. Two types of pressure compensation are available: The optical span filter for the Multiwave Photometer provides the operator with an alternate means of checking the analyzer performance. It is most often used when the process makes it difficult to readily acquire a calibration standard, and when normal calibration methods would be difficult to accomplish or unsafe. Gas Law Compensation Pressure Compensation is based on the Ideal Gas Law and requires no calibration. It is used in selected applications where the gas sample does not have a fine line spectrum. Some common compounds with fine line spectra are carbon monoxide, carbon dioxide, methane, and ammonia. Empirical Compensation Pressure Compensation is based on experimental data. It requires calibration in the factory lab. This type of compensation is recommended on suppressed ranges and on applications susceptible to pressure broadening effects.

12 PFO3372 Fiber Optic Process Photometer This option involves interfacing with the Multiwave Photometer. The Fiber Optic Waveguide eliminates the need to transport sample to the analyzer. With this option, the light is transmitted via one waveguide to the sample. Then, a second waveguide returns the samplemodified light from the sample cell to the detector. Fiber Optics is an effective option in applications where... the sample stream is highly toxic highly corrosive products are analyzed streams are at high temperature streams are at high pressure the sample is at high vacuum the sample needs to remain sanitary a fast response time is required all of the above, or any combination of the above conditions apply Moisture applications such as water in acids, water in methanol, water in hydrocarbons, or hydrocarbons in water are good candidates for the fiber optic option. Applications that require a fast response time, such as monitoring the Lower Explosive Limit (LEL) for hydrocarbons in air, should also be considered. NOTE: Current applications of fiber optics are limited to the UV/Visible ( nm) and NIR ( nm).

13 VN2300 Communications Board The ABB Process Photometer features a VN2300 (formerly VIstaNET) Communications Board option. The VN2300 Remote User Interface (RUI) presents the user with a graphical interface for operation and configuration at a remote PC. The following operations are available via the RUI at the remote PC: Remote Maintenance via modem. Direct calculation of Matrix Coefficients Direct calculation of Linearity Coefficients. Reports, Tables and Applications Data Sheets can be printed and reviewed. Ambient Air Applications The PIR3502 Photometer interfaced with a multireflective long path gas cell can be used in ambient air monitoring applications. Multiple stream Sample Handling Systems combined with the ABB Process Photometer have been used to measure up to 20 points for the detection of toxic gases ppm Acrylonitrile; 0 50 ppm Stryrene 0 25 ppm Ethylene Oxide; 0 25 ppm Propylene Oxide 0 50 ppm Phosgene 0 25 ppm Carbon Tetrachloride; 0 25 ppm Chloroform ppm Divinylbenzene; ppm Ethylbenzene ppm

14 Final Product Blending Optimize your Gasoline and Diesel Blender with Field-proven ABB FT-NIR Technology Final Product Blending Product blending is an important technique used in the refining industry. It is the final stage in the conversion of crude oil into useful fuels. The blender mixes together several streams from various process units to provide fuel that meets government, international or customer specifications. Due to the fact that is the final stage in a refinery process, the optimization of this process is vital. Regardless of how efficient the upstream process units may be, this can be negated if poorly optimized blending produces a substandard fuel. In many respects it is the most important process to optimize and can also bring the maximum benefits in terms of payback. ABB has a vast amount of experience in providing optimization of blending units. The first stage in optimization of the unit is measurement of the properties themselves that are to be optimized. ABB s field-proven FTIR solution can deliver several benefits to the refiner. ABB s reliable, rugged NIR spectrometer is the heart of the analysis system. It uses the latest and most advantageous NIR spectroscopy technique, Fourier Transform Near Infrared (FT-NIR) spectroscopy. The ABB spectrometer is specially designed to operate in process environments so the user does not need to make allowances for a fragile optical instrument.

15 Extractive Analyser Sample System for Final Product Blending Application This spectrometer is housed in a rugged industrial enclosure with hazardous area certification. A fully incorporated temperature controlled sample system provides stable, accurate results. Full Windows process software is included to provide outputs to the plant DCS system (ModBUS, OPC, 4-20mA). ABB will work in close partnership with you to develop customized solutions that meet your specific needs. We offer a wide range of customer support services, including method development, in-house and on-site personnel training, as well as start-up and after-sales service. ABB has been manufacturing FTIR spectrometers and accessories since its foundation in By intensive research and development activities, and through a close partnership with our customers, we have developed a unique expertise in quantitative analysis using FTIR and FT-NIR technology. As a result, we are now the world leader in FTIR and FT-NIR process analyzers. We have an installed base of over 150 currently operational analyzers used in the refining blending field and other refinery applications. We have an accumulative database of approximately 40,000 spectra that can accelerate the implementation of any new blending project. Our expertise and experience means we can confidently claim to be a world leader in this field. Common Operating/Problems Final product blending represents perhaps the most quality-critical aspect of refinery operation. Tight product quality characteristics are defined, and must be met for product release. If these criteria are to be met economically (i.e. with minimized high-cost product giveaway, and by the use of the available blending feedstocks with the lowest cost), then both rapid and accurate on-line product (and feedstock) property measurements are necessary. The measured product qualities are then available in real-time for feeding to an on-line blending optimizer, thus ensuring the most economic blending operation to achieve blend targets. Conventionally, this has been done with a large variety of physical property analyzers and on-line engines to monitor blend properties and octane. These sets of analyzers are extremely expensive, in terms of both capital and ongoing maintenance. Solution / Benefits The ABB range of Process FT-NIR analyzers for on-line gasoline and diesel blend optimization allows for rapid multi-stream and multi-property quality determination of gasoline and gasoil blending components and final product streams. The calibration methodologies employed, and the transferability of calibrations and calibration databases between ABB laboratory analyzers and process blending analyzers, allow for rapid project startup, and minimize the amount of site-specific calibration work needed. For these reasons, the cost of ownership can be significantly reduced, compared with conventional final product blending analysis methods. By accurately measuring final product qualities in real-time, the analyzer will allow feeding any on-line Advanced Blend Control blend optimizer with the required product qualities, will minimize product re-blends and quality giveaway, and will allow the use of lower-cost feedstocks while still meeting final product quality targets. Accurate measurement of blending component qualities as they arrive at the blend header will also allow the optimizer to determine the best achievable blend order. 2

16 Gustave, process manager. Knew where to turn to fuel strong returns. Hero N Gustave is responsible for optimizing the blending margin at a petroleum refinery. A lot rides on the monitoring equipment he selected. Substandard blends mean additional re-blend costs; over-target blends mean reduced profit margins. With their excellent reputation for realtime, on-line gasoline blend optimization, ABB s FT-NIR refinery process solutions caught Gustave s attention. And once installed, the millions of dollars in savings ABB s solution generated caught the attention of Gustave s superiors. FT-IR Optimizing Productivity. Learn how ABB Analytical helped Gustave overcome technical challenges.

17 Gustave, process manager. Knew where to turn to fuel strong returns. Primary responsibilities: 1. Maximize refinery s blending margin. 2. Meet final blended product qualities required by legislation. 2. Avoid shipping over-target products or incurring re-blend costs by blending sub-standard gasoline. The challenge Gustave needed an on-line quality monitoring solution to enable consistent, on-target blends, using the most economical blending recipe from his pool of blending components. ABB s FT-NIR analyzers have an excellent reputation for realtime, on-line gasoline blend optimization. However, Gustave was concerned calibration models could be difficult to develop and maintain. Custom calibrations used by on-line analyzers must be developed in the laboratory on a different instrument. Any instabilities or photometric non-linearities in the instruments make it difficult to develop reliable calibrations and transfer these calibrations directly from the laboratory analyzer to the on-line analyzers. The solution With easy-to-use software, ABB s laboratory analyzer (MB3600-HP10) simplifies hydrocarbon sample determination and calibration development. Their analyzer also has pre-defined calibrations for blended gasoline, diesel, reformate and naphtha. It was crucial to transfer the calibrations developed in the lab directly to the on-line process analyzers. ABB s manufacturing methods ensure all their laboratory and process FT-NIR analyzers provide identical absorbance spectra. This guarantees calibration transferability from lab to process without additional calibration effort or data manipulation. Finally, ABB offers a full range of custom calibration modeling services and application support to their customers a great help in getting started. Why I chose ABB FT-NIR analyzers: Reliable real-time process monitoring with no drift ABB s analyzers are robust and deliver consistently reliable results. Calibration transfer between instruments is also guaranteed. Simplified analysis and calibration development in the lab With easy-to-use software and pre-calibrated analytical procedures, the MB3600-HP10 laboratory analyzer simplifies in-lab hydrocarbon sample determination. Additional custom calibrations can easily be developed for a wide range of products. Minimal preventive maintenance All ABB FT-NIR analyzers are permanently aligned. The new MB3600-HP10 is fitted with leading-edge long-life solid-state laser metrology which completely eliminates the need for laser replacement; on-line FT-NIR analyzers feature user-replaceable modular components for easy preventative maintenance in the field. Local technical support We used a locally certified ABB partner for installing and commissioning the on-line analyzers. Comprehensive calibration modeling and training services ABB offers a full range of custom modeling services and chemometrics training for customers. The results ABB worked closely with our personnel to define the optimal solution. Six months after our blending optimization project received the go-ahead, two on-line FT-NIR analyzers were installed. In the meantime, custom calibration models were developed and validated in the lab using the MB3600-HP10. After a short period of QMI validation, the on-line analyzers were qualified for blend optimization and product release. My control engineer said without the in-blend optimization using validated on-line blend quality inputs from process FT-NIR, the required multiple quality constraints could never have been met simultaneously. Gustave s refinery director estimates using ABB s advanced process control on their blend operations adds at least $6 million per year to the refinery s bottom line. Gustave The MB3600-HP10 Laboratory Analyzer Hardware Software Accessories for both QA/QC analysis and chemometrics development Pre-defined calibrations for blended gasoline, diesel, reformate and naphtha. For further information regarding ABB products and services visit * Each ABB Hero Story is a real business case. In order to maintain confidentiality, the name of the hero has been changed and the company name is not mentioned. ABB Analytical 585 Charest Blvd East, suite 300 Quebec, (Quebec) G1K 9H4 Canada Phone: (North America) ftir@ca.abb.com Web: Printed in Canada 07/09 Copyright 2009 by ABB. All Rights Reserved. Registered Trademark of ABB TM Trademark of ABB