GE Analytical Instruments (GEAI) Process TOC Applications

Transcription

1 GE Analytical Instruments (GEAI) Process TOC Applications

2 Agenda Process TOC Product Introduction Industry and Application Overview Key Applications Case Studies 2

3 Process TOC Product Introduction

4 Brief History of TOC for Industrial Apps Strong value proposition / ROI for process control, leak detection, WW system optimization. Early industrial online TOC instruments were lab instruments extended into online applications with little understanding of the challenging sample matrices and punishing physical environments. Most early attempts to extract value from online TOC monitoring failed due to under-designed instrumentation, poor uptime, high COO. Today s instruments are designed specifically for the harsh sample and environmental conditions experienced in HPI/CPI applications. Industrial components, electronics, machined parts Robust sample handling NEMA 4x; IP-56; Class I / Div II; ATEX; RMD (Remote Monitoring and Diagnosis) Analytical techniques designed for high salts and particulates 4

5 Sievers InnovOx Super Critical Water Oxidation Sample matrices: Brine Cellulose InnovOx SCWO Reactor Humic Acid Particulates 10/16/2013 5

6 GE s Sievers TOC Analyzer & Sensors Line 6

7 Process TOC Analyzer Technology Comparison SCWO (GE) Two-Stage Advanced Oxidation (Ozonation) Combustion UV/Persulfate Brine and salt Handle solution with up to 30% chloride and 12 % calcium Leads to analyzer failure due to collection of unoxidized particulates in the furnace Reduces persulfate oxidation potential with concentration as low as 0.05% Auto Self Cleaning Auto self cleaning Not available, typically requires analyzer to be offline for 1 hr for manual cleaning Calibration Stability Allows a 12-month calibration interval Allows a 6-month calibration interval Requires calibration every 2-3 days due to furnace buildup and IR bench contamination Requires calibration every 2-3 days due to UV light source scaling that causes incomplete oxidation and drift Gas Needed Clean tank/house air Zero grade air + oxygen Zero grade air + oxygen Nitrogen, zero grade air Reagent Needed Flexible supplier Sole source supplier for catalyst Flexible supplier Flexible supplier Capital Cost Medium High Low to High, varies by vendors Low to Medium 7

8 Process TOC Industries & Applications

9 Sievers InnovOx TOC Analyzer: Industries Hydrocarbon Processing Chemical Processing Food & Beverage Microelectronics Municipal Water and Wastewater Pharmaceutical 9

10 Process TOC Application Overview Wastewater process optimization Nutrient loading MBR optimization Prevent exceeding discharge limits COD/BOD correlation continuous, real-time monitoring. Heat exchanger leak detection Detect product contamination in steam feed and condensate Cooling water contamination Production process control Surface / storm water runoff 10

11 Process TOC Application Overview MAKE-UP WATER WATER REUSE SOURCE WATER Challenges: amount/scarcity, quality (TSS, TDS, organics) UF/RO filtration Clarification chemicals Mobile/Water Outsourcing (BOO) TOC analyzers UTILITIES Challenges: system stress from pushed operations Cooling chemicals Boiler chemicals TrueSense* monitoring and control TOC analyzers WASTEWATER Challenges: varying levels and types of organics, varying TSS Wastewater chemicals UF/MBR ZLD-thermal TOC analyzers PRODUCTS FEEDSTOCK PROCESS Challenges: maintain production for full run length Antifoulants Corrosion inhibitors Antifoams Demulsifiers Oxygen scavengers TOC analyzers 11

12 Wastewater Influent TOC application locations: After API separator or before EQ tank (Front-end) Prior to bioreactor (Pre-biological) Objective: recognize if organic overload/upset in the influent to WWTP The capacities of the bioreactor or EQ tank are designed based on organic load in wastewater. 12

13 Wastewater Effluent BOD or COD is time consuming analysis and does not provide continuous analysis like TOC TOC-COD Correlation The WWTP operators typically need real-time data for process optimization, and to retain, divert, or dilute discharges prior to causing damage COD (ppm) Correlating TOC to BOD/COD allows a facility to better manage their WWTP and avoid paying high organic load surcharges or penalties TOC (ppm) 13

14 Potential TOC Locations for Reuse or Direct Discharge TOC Applications 1. Monitor if organic overload/upset in the influent to bioreactor 2. Monitor upstream treatment efficiency, protect RO and insure discharge or reuse quality Wastewater 1 TOC MBR Simplified Treatment Process 1 TOC TOC Tertiary Filtration Process 2 High Quality Effluent for RO Feed TOC 2 14

15 Potential TOC Locations for Refinery WW Treatment Sour Stripped Water oil Slop Tanks solid s DGF Skim Centrifuge, Press wat er ski m wat er ski m Solids To Sludge Handling Desalter NESHAP Stripper API Dissolved Gas Flotation Aeration Tank(s) Clarifier(s) 3 o Treatment or Reuse Discharge oil Process Units solid s solid s solid s Product Sludge Handling 15

16 Leak Detection TOC can demonstrate the ability to accurately measure an upset and resume running condensate or detect any leads in heat exchangers for cooling water. TOC can help companies decide whether additional treatment is needed for stormwater or if there is any contamination in the stormwater 16

17 Chemical Dosing Optimization Removal of metals such as selenium in sour stripped water requires the addition of a chemical oxidant (e.g. hydrogen peroxide) prior to coagulation/settling. In this application, background organic carbon is an oxidant scavenger that greatly reduces the efficiency of the treatment process. Amines or other organic carbon reacts with the oxidant before the target compounds (e.g. selenium). An InnovOx TOC Analyzer helps optimize the oxidant dose for the treatment process, thereby greatly increasing the efficiency of the process. In some cases, companies can reduce the oxidant dosage and therefore reduce cost. The cost of oxidant exceeds $100,000 per year at some facilities. In addition to the sour water stripper process, optimizing chemical dosing in the tertiary wastewater treatment process (chemical oxidation polishing step) using TOC is possible. 17

18 Case Studies

19 WW Influent Monitoring Customer Summary Case Details Industry Segment: Main Product: Applications: Food & Beverage Beer, Misc. Beverages WW Influent WW Process Optimization Two WW treatment plants are located at the customer site. One is for process WW, and the other one is for general WW and domestic WW from the city. InnovOx On-Line TOC analyzers are installed at each influent monitoring point, prior to the activated sludge biological treatments. The monitoring data help to understand any organic loading spikes from upstream, and make necessary adjustment of oxygen, ammonia dosed to the system operations ppm TC in influent of general WW, 900-1,000 ppm TC in influent of process WW 19

20 WW Process Control & Effluent COD Correlation Customer Summary Case Details Industry Segment: Main Product: Applications: Food & Beverage Bottling Plant Soft Drinks 1. Control nutrient dosing 2. Correlation to COD (Effluent) Monitor influent to WW plant (GE Zeeweed MBR). Based on TOC value, customer controls ammonia dosed into equalization (EQ) tank. EQ tank is undersized, has to turn it over 3-5 times per day, critical to understand organic loading. Typically run 1200 ppm, but can spike above 3000 ppm (alarm at 3000 ppm). COD samples run 6 times per day. COD:TOC correlation study is done with a result of COD:TOC at 3:1 ratio. Customer uses TOC results to monitor effluent quality. 20

21 WW Bioreactor Optimization Customer Summary Case Details Industry Segment: Product: Application: Food & Beverage Beer, Misc. Beverages WW Process Monitoring Control algorithms around TOC to ensure stable bioreactor operation TOC detects increases on reactor effluent, recommend decrease reactor flow rate to prevent biomass overflow & maintain solid retention time. Helps retain biomass Improve biogas production Improve organic removal Reduce chemical usage by using the control actions of EQ tank level, recycle ratio, reactor flow, and ph control. 21

22 Steam Condensate Spill Detection Customer Summary Case Details Industry Segment: Application: Hydrocarbon Processing Spill Detection Steam condensate is used for boiler feed water in the process. Any hydrocarbon leak from heat exchanger to condensate damages the boiler integrity and brings downtime to the process. The customer smelled/observed the oil sheen in the condensate, however, is not able to estimate the time of release and quantify the organic loading. Without the data, it is very challenging to design a treatment system to protect the boiler. InnovOx On-Line TOC Analyzer provided to the customer as an onsite demo gives the baseline TOC reading of ~2 ppm, several spikes of TOC up to ppm observed during the first two weeks after installation. 22

23 Cooling Water TOC Monitoring Customer Summary Case Details Industry Segment: Application: Cogen Plant Spill Detection Problem: the most common environmental problem associated with cooling water is the leakage of hydrocarbons into the cooling water from aging heat exchangers, which subsequently causes high BOD/COD levels in the blowdown. Due to increasing environmental concerns and the impacts of the inherent cooling tower problems, some state (TX) permits require monitoring the cooling water system for benzene and TOC in the return cooling water. Solution: as a good engineering practice, and to ensure that the hydrocarbon leakage can be detected early, a plant installs an online TOC analyzer in the common cooling-water return header and provide sample connections at different return subheaders for easy leak identification. 23

24 For more information Industry Application Notes/Case Studies: Product information: Quote Request or Questions: 24