Gas Analysis Solutions Pipeline safety, advanced process control and in-spec production

Transcription

1 Products Solutions Services Gas Analysis Solutions Pipeline safety, advanced process control and in-spec production

2 2 Gas Analysis Solutions Endress+Hauser technology portfolio extended to field of gas analysis Expanded process analysis capabilities and possibilities ANALYTICAL RANGE Turbidity Viscosity Density Conductivity ph *Concentration Composition LIQUID GAS NEW TECHNOLOGIES AND COMPETENCIES ACQUIRED Extractive: single-component TDLAS In-line: multi-component Process Raman Spectroscopy An Endress+Hauser Company Sample tube to analyzer Fiber optics Sample extraction AirHead Probe Hydrocarbon gas stream *LIQUID concentration: TOC, oxygen, colorimetry, absorbance Industry and technology-driven investments Key trends supporting the decision to enter the field of process automation solutions include: A shift in patterns of oil and gas production Industries moving from lab to process measurements New, robust laser optical technologies New technologies are complementary TDLAS 1 measures trace levels of a contaminant from sub-ppm v level to low percentage levels Raman measures multiple-components starting at concentrations of > 0.1% Our evolutionary approach Investments in internal and external support structure in focused markets such as application experts, service specialists and project support Multiply proven, fully documented TDLAS applications with sustainable return of investment Introduce field-proven Optograf analyser to the syngas-related industries to establish solution as an alternative to GCs 2 1) Tunable Diode Laser Absorption Spectroscopy 2) Gas Chromatograph

3 3 Natural gas Monitoring contaminants to protect pipelines from corrosion, blockage by hydrate formation and assure quality specifications for custody transfer Gas processing Monitoring contaminants is critical for process optimisation and gas quality Moisture H 2 O in natural gas pipelines Low moisture content is critical to meet quality specifications and to protect pipelines from corrosion - measuring ranges starting from ppm v. Traditional approach High levels of solid and liquid contaminants and varying concentrations (glycol, methanol, compressor oil, sulfur compounds) challenge measurements of moisture. Sensors relying on the adsorption onto sensitive surfaces have wet-up or dry-down delays Contaminants may destroy some moisture sensors Cross-interference affects moisture readings Al 2 O 3 sensors are slow and subject to other components in natural gas Our solution SpectraSensors Tunable Diode Laser Absorption Spectroscopy (TDLAS): The rugged solution used in natural gas pipelines with very little maintenance, no interference, and with no detrimental effects from glycol, methanol, amines, H 2 S, moisture slugs, etc. Unique benefit Accurate, non-contact measurement with no wet-up or dry-down delays, in real-time Calibration-free, no routine maintenance Independent from glycol, methanol or amine No consumables Hydrogen sulfide H 2 S in amine scrubber outlet One of the first steps in a gas plant is the reduction of acid gas components - measuring ranges starting from 0-10 ppm v. Traditional approach Lead acetate tape analysers work but have high maintenance requirements to replace and dispose of the tapes in an environmentally safe manner On-line gas chromatographs take 3-6 minutes between measurement updates and do not sense rapid changes. OPEX are high due to consumption of carrier gas and flame fuel cylinder gases Broadband UV light sources and narrow band pass filters are prone to interferences from changing background concentration Our solution High resolution SpectraSensors TDLAS technology eliminates errors from interferences encountered with other spectroscopic techniques. Unique benefit Differential spectroscopy provides accurate low-level measurements in complex hydrocarbon streams Factory calibration ensures stable, long-term in-field operation Faster response protects pipelines from H 2 S contamination Analyte H 2 S H 2 O More key natural gas applications, please refer to the table on page 9 Typical Ranges 0-10 to ppm v to 2500 ppm v 0-5 to 0-20% Analyte H 2 S H 2 O More key natural gas processing applications, please refer to the table on page 9 Typical Ranges 0-10 to ppm v 0-10 ppm v ppm v to 0-5%

4 4 Gas Analysis Solutions Liquefied natural gas (LNG) Monitoring impurities in gas feed to the cold box to ensure reliable liquefaction and on-time shipments Petrochemicals / olefins / ethylene Measuring impurities in C 2 streams fraction to prevent C 2 splitter contamination and prevent going to flare due to not meeting ethylene product specifications Moisture H 2 O in molecular sieve outlet Gas moisture concentration at outlet of desiccant dryers to prevent freeze-up of liquefaction train. Traditional approach Electrochemical sensors are affected by hydrocarbons and other contaminants requiring frequent replacement Quartz crystal moisture balances are sensitive to contaminants and have high OPEX Our solution SpectraSensors non-contact laser is immune to damage and has no wet-up or dry-down delays even when the concentration changes dramatically. Unique benefit Reliable trace-level (sub-ppm v) measurement with Differential Spectroscopy Periodic self-validation with an integral, internal permeation tube avoids downstream up-set Exceptionally fast response to detect moisture breakthrough Acetylene C 2 H 2 in C 2 ethylene Control of hydrogenation conditions in the acetylene converter measuring ranges starting from 0-5 ppm v. Traditional approach Speed of response of GCs for acetylene is not rapid enough to prevent upset conditions. Potential to contaminate the C 2 splitter or process gas which then must be sent to flare with loss of revenue. Our solution SpectraSensors TDL analysers respond to concentration changes in seconds versus minutes, with repeatability comparable to GC Optimisation of H 2 utilisation Unique benefit Continuous, analyte-specific measurement versus batch measurement of multiple components Fewer acetylene conversion unit upsets with less product loss to flare More key LNG applications, please refer to the table on page 9 More key Olefins applications, please refer to the table on page 9 Analyte H 2 S H 2 O Typical Ranges 0-10 ppm v 0-2 to 0-10 ppm v Analyte C 2 H 2 H 2 O Typical Ranges 0-10 to ppm v 0-10 ppm v ppm v NH ppm v H 2 S ppm v ppm v

5 5 Refinery Syngas-related industries Measuring composition and impurities in refinery gases to optimise process efficiency and hydrogen quality Measuring composition for optimising syngas production, process intermediates and end products H2S in refinery fuel gas Refinery fuel gas is a collection of light hydrocarbon gases. To meet environmental regulations, the concentration of H2S in fuel gas is monitored before burning instead of SO2 after combustion. Typical range: ppmv. Raw syngas in primary reformer outlet Raw syngas is the first intermediate product; measurement of the components H2, CO, CH4 and CO2 are used to monitor the H2 and CO2 and allow optimisation of the steam/carbon ratio for controlling the reformer. Traditional approach On-line GC has high consumption of carrier gases and requires frequent maintenance and calibration Lead-acetate tape analysers use consumables that require maintenance and special handling to dispose of tape which is classified a hazardous waste Traditional approach Gasifier outputs are dirty streams sampling and speed of response are main concerns in this process of hazardous and pressurised gases. Typically applied technologies like Process GC or Mass Spectrometry (MS) require transporting and conditioning the sample at both the sample tap and sample conditioning panel close to the analyser. Specifically, in this application, the use of a Dynamic Reflux Sampler (DRS) or alternative liquid and particulate removal system is mandatory. Protecting the GC or MS analysers from liquid carry-over is the main challenge as this can damage columns in a GC or the ionisation chamber in a MS. Our solution Accurate measurements by SpectraSensors unique Differential TDLAS Spectroscopy helps address changing fuel gas composition with automated 2-point daily validation. Unique benefit Lower cost of ownership Safer to operate No disposal costs More key refinery applications, please refer to the table on page 9 Analyte Typical Ranges H 2S 0-10 to ppmv H 2O 0-10 to ppmv Our solution Continuous measurement using a Raman Optograf Analyser and the OptoDRS sample conditioning. Unique benefit Robust spectroscopic capability to measure simultaneously all syngas components, including H2 and N2 Front end sampling to deal with particle-laden or steam-saturated samples, ensuring no liquid carry-over Saves cost on carrier gas and calibration efforts Improved safety, since no process gas is transported to a shelter analyser house For more key syngas related applications, please refer to the table on page 11 Multi-Component Analysis H2S, NH3, CO2, CO, H2, N2, CH4, CH3OH, C2H6, C3H8, C4H10

6 6 Gas Analysis Solutions Engineered gas analysis solutions Endress+Hauser and SpectraSensors have the specialised expertise required to deliver complete turn-key solutions for your critical gas analysis applications 1 Sample extraction and transfer The quality of process measurements is directly affected by site-specific conditions. Accuracy and repeatability can be compromised if sample extraction and transfer components are not properly designed and fabricated for an application. SpectraSensors sampling probes and heated transfer lines constructed of electropolished stainless steel with inert surface treatment prevent adsorptive losses of sulfur species and moisture, which is necessary for performing trace level measurements. 2 Sample conditioning and analysis Process gas streams often require conditioning to prevent introduction of liquids or particles into an analyser. Sample conditioning systems are designed to protect the analyser and control sample flow rate, pressure, and temperature conditions to optimise spectroscopic performance. Example - gas sample handling for TDLAS 1 Sample extraction and transfer 2 Sample conditioning and analysis Heated sample cabinet Sample Probe Filter Heat Traced Bypass Filter Sensor or Analyzer Process Pipe Bypass Vent

7 7 Combining core competencies to improve process control Ensuring operational efficiency and a positive return on investment 3 Analyser protection and area classification The operating environment in which an analyser will be deployed determines the type of weather protection and analyser housing required to meet a plant s area safety classification. Analyser configurations are available to comply with hazardous area classifications around the world. SpectraSensors can design and build protective racks for analysers that incorporate utility headers, power distribution panels, lighting, communication hardware and Programmable Logic Controllers (PLCs) to supply complete turn-key solutions. SpectraSensors Endress+Hauser Gas Analysis Solutions Kaiser Optical Systems Endress+Hauser Reducing risks and delays through standardised processes for engineered solutions and project execution Know-how in PLC-programming and advanced communication protocols; OPC, UA or ethernet IP SpectraSensors First to deploy and prove TDLAS technology in hydrocarbon processing industries Expertise in measuring contaminants in complex hydrocarbon gas streams with installations worldwide Customised solutions provided and supported by regional Centers of Competence or qualified integrators Regional service points guarantee expert level support Kaiser Optical Systems Fiber-optic Raman sensors designed to allow our customers to conduct effective in-line process analysis Robustness, reliability and performance are hallmarks of Kaiser s Raman technology Over 10 years of experience in on-line process control

8 8 Gas Analysis Solutions SpectraSensors, Inc. Leading global provider of laser-based on-line analysers for process control and monitoring applications with an installed base of over 7,500 units. Company products are specifically designed to improve process efficiency, throughput, safety, and to meet product specifications in gas production and downstream processes. Measurement principle SpectraSensors' analysers utilise laser absorption spectroscopy to detect and measure the concentration of analyte in a process gas stream. This technique has been applied to gas measurements since the laser was first invented over 40 years ago. Advances in semiconductor lasers have made this technology economically viable for measurement of H 2 O, H 2 S and in natural gas at the special wavelengths that are required. Benefits compared to traditional technologies Non-contact measurement with laser and detector isolated from process gas avoids fouling for reliable long-term operation TDLAS analysers selectively measure trace level contaminants in hydrocarbon streams, unlike capacitance or quartz crystal microbalances which provide only inferred measurements An exceptionally fast response to changes in analyte concentration (t 90 in seconds versus minutes) provides real-time data for process control and optimisation TDLAS analysers require virtually no consumable items unlike gas chromatographs or lead acetate tape analysers, resulting in a lower cost of ownership and service burden on technicians Extractive sampling and fast analyser response time supports stream switching applications Unique SpectraSensors TDLAS Differential spectroscopy and advanced signal processing algorithms provide accurate measurements in gases with complex backgrounds Automated on-line analyser validation with integral permeation device for tracelevel measurement applications Factory calibration using gas blended to match process gas composition ensures accurate in-field measurements and stable long-term operation Advanced laser diode technology enabling selective and specific measurement of analytes in hydrocarbon gas streams Analyser sample conditioning systems optimised to provide reliable measurements in diverse process gas streams H₂O Absorption at different concentrations Absorption coefficient λ = 2 μm λ [Wave length] SS2100 and SS2100a single channel analysers; SS2100i-2 two-box single channel

9 9 Application guide - TDLAS analysers Industry Analyte Application Natural Gas Typical Measured Range(S) Application Note # H 2 O Moisture in Natural Gas ppm v ppm v Carbon Dioxide in Natural Gas 0-5% 0-20% H 2 S Hydrogen Sulfide in Natural Gas 0-10 ppm v ppm v O 2 Oxygen Measurements ppm v 0-50% H 2 O Water Measurements in Desiccant Dryer Outlets 0-10 ppm v Gas Processing H 2 O Water Measurements in Natural Gas Product (Product Purity/Residue Gas) 0-10 ppm v H 2 O Moisture in Fractionation/NGL Products (Y-grade, ethane, E/P mix, propane, or butane) 0-10 ppm v 35001, 35101, 35201, 35301, Carbon Dioxide in Amine Unit Outlet (Sweet Gas) ppm v Carbon Dioxide in Fractionation/NGL Products (Y-grade, ethane, E/P mix, propane, or butane) Carbon Dioxide in Raw Natural Gas Feed ppm v 0-5% ppm v 35003, 35103, 35203, 35303, H 2 S Hydrogen Sulfide in Raw Natural Gas Feed (Produced Gas) ppm v ppm v H 2 S Hydrogen Sulfide in Natural Gas Product (Product Purity/Residue Gas) 0-20 ppm v H 2 S Hydrogen Sulfide in Amine Scrubber Outlet 0-10 ppm v ppm v H 2 S Hydrogen Sulfide in a Solid Scavenger Outlet ppm v H 2 S Hydrogen Sulfide in Fractionation/NGL Product (Y-grade, ethane, E/P mix, propane, or butane) 0-20 ppm v 0-50 ppm v 35002, 35102, 35202, 35302, H 2 O Water Measurements in Dry LNG Feed Gas (LNG Desiccant Dryer) 0-10 ppm v LNG H 2 O Water Measurements in LNG Product (LNG Receiving Terminal) 0-10 ppm v Carbon Dioxide in Amine Unit Outlet (LNG) ppm v H 2 S Hydrogen Sulfide in an LNG Amine Unit 0-10 ppm v H 2 O Water Measurement in Pure Ethylene 0-10 ppm v H 2 O Moisture in Polyethylene Feedstock 0-10 ppm v H 2 O Water Measurement in Pure Propylene (Steam Cracker) 0-10 ppm v Olefins (Petrochemicals) C 2 H 2 Acetylene Measurement in the Mid Bed of Back End Acetylene Converters ppm v C 2 H 2 Acetylene Measurement at the Outlet of Back End Acetylene Converters 0-5 ppm v C 2 H 2 Acetylene Measurement in Pure Ethylene 0-5 ppm v NH 3 Ammonia Measurement in Pure Ethylene 0-5 ppm v H 2 S Hydrogen Sulfide in Caustic Wash Tower Inlet ppm v Carbon Dioxide in Caustic Wash Tower Inlet ppm v H 2 O Water in Hydrogen Recycle for Refinery Catalytic Reformer H 2 Recycle Streams 0-50 ppm v (control) ppm v (trend) H 2 O Moisture in Propane/Propylene Mix 0-10 ppm v H 2 O Moisture in Alkylation Feed C ppm v Refinery H 2 O Moisture in Instrument Air 0-10 ppm v H 2 S Hydrogen Sulfide in Propane/Propylene Mix 0-10 ppm v H 2 S Hydrogen Sulfide in Flare Gas 0-10 ppm v ppm v H 2 S Hydrogen Sulfide in Fuel Gas ppm v Syngas H 2 S Hydrogen Sulfide in Hydrogen Recycle for Catalytic Reformer 0-50 ppm v ppm v Carbon Dioxide in GTL Syngas (Synthol Process) (Coal Liquefaction (CTL)/ Benefield Outlet) ppm v ppm v Carbon Dioxide in a Coal Liquefaction (CTL)/Gassifier Outlet 0-50% 65903

10 10 Gas Analysis Solutions Kaiser Optical Systems Inc. A leader in Raman spectroscopy, spectrographic instrumentation and patented holographic technology with more than 20 years experience. Principal products include holographic components for avionics, astronomy and ultra-fast sciences. Measurement principle Raman spectroscopy is a form of vibrational spectroscopy, much like infrared (IR) absorption. However, whereas IR bands arise from a change in the dipole moment of a molecule due to the absorption of light with the molecule, Raman bands arise from a change in the polarisability of the molecule due to scattering of the light by the molecule. This means that these observed bands (corresponding to specific energy transitions) arise from specific molecular vibrations. When the energies of these transitions are plotted as a spectrum, they can be used for identification as they provide an optical fingerprint of the molecule being measured. Real-time on-line composition analysis down to 0.1% per component Laser light travels via fiber-optic cables to a detector, eliminating need to transport the sample. Coupled with the Optograf analyser, which does not require a climate controlled house, CAPEX is greatly reduced. Although it has many analytical similarities with a GC, the Optograf analyser does not require any consumables and has a low OPEX Can replace up to 4 analysers with a single base unit equipped with 4 probes Typical Optogram spectrum Counts [10 3 ] H2 CO Typical OptoAST interface to a process gas stream Optical fiber <100 m CO N2 H2S CH4 NH3 Raman Shift 1 Optograf Gas Analyser The Optograf is a turn-key laser-based analyser that provides quantitative chemical composition measurements using Raman spectroscopy. The design of the Optograf Gas Analyser incorporates customer requirements for serviceability and hazard-area certification, as well as a compact footprint and minimal utilities consumption. 3 2 Integrated AirHead probe Weather enclosure 1 2 AirHead gas sampling probe The AirHead fiber-optic probe is optimised for gasphase / head-space monitoring. By using fiber-optics the measurement is brought to the sample (the analyser can be located up to 100 meters from the sample point), eliminating the need for a complex or maintenance intensive sampling system. Rugged fiber-optic cables allow for easy installations both indoors and outdoor. 3 OptoAST sample interface - optional The OptoAST (At Sample Tap) sampling interface integrates the AirHead gas sampling sensor with a NeSSI 3D sampling platform. Traditional analysers utilise an extractive sampling approach to transport a sample to the analyser. The OptoAST allows realtime, true pipe centric analysis which minimises the challenges associated with process sampling. Features : No sample transfer lines required, no lag time Can operate at process pressure - sample can be returned to process (low pressure line), no flare, waste or disposal Compatible with integrated calibration or validation gas input OptoDRS sample interface - optional, not shown Combines all the benefits of the OptoAST with a Dynamic Reflux Sampler (DRS) to handle hot, particle-laden, steam-saturated process streams.

11 11 Application guide - Raman Optograf analysers Industry Process Plant Measurement Parameter Stream Sample Fertiliser Bulk Gas Suppliers Refining Syngas SNG Methanol Ammonia HyCO Plants H2 Production SNG Methanol Plant Ammonia Production Analytics Overview Sampling Interface Application Note Carbon Number Natural Gas Feed to Primary Reformer OptoAST AM1 BTU Fuel Gas to Reformer Furnaces OptoAST AM2 Composition/CH 4 Raw Syngas - Primary Reformer Outlet OptoDRS AM3 Composition/CO Raw Syngas - Secondary Reformer Outlet OptoDRS AM4 Composition/CO High Temperature Shift Converter Outlet OptoDRS AM5 Composition/ Low Temperature Shift Converter Outlet OptoDRS AM6 Composition/ Absorber Outlet - Methanator Inlet OptoAST AM7 Composition/H 2 /N 2 Methanator Outlet - Purified Syngas OptoAST AM8 H 2 /N 2 Ratio Ammonia Converter Feed Stream OptoAST AM9 Composition/Impurities Ammonia Converter Exit Stream OptoAST AM10 CH 4 Impurities Synthesis Loop Purge Gas OptoAST AM11 HyCO Production Analytics Overview Carbon Number Natural Gas Feed to Primary Reformer OptoAST HY1 BTU Fuel Gas to Reformer Furnaces OptoAST HY2 Composition/CH 4 Raw Syngas - Primary Reformer Outlet OptoDRS HY3 Composition/CO Raw Syngas - Secondary Reformer Outlet OptoDRS HY4 Composition/CO High Temperature Shift Converter Outlet OptoDRS HY5 Composition/ Low Temperature Shift Converter Outlet OptoDRS HY6 Composition/ Absorber Outlet - Feed to PSA OptoAST HY7 Composition/H 2 /N 2 PSA Unit H 2 Stream OptoAST HY8 CH 4 Leakage Recovery Stream OptoAST HY9 Captive Hydrogen Production Analytics Overview Carbon Number Natural Gas Feed to Primary Reformer OptoAST HH1 BTU Fuel Gas to Reformer Furnaces OptoAST HH2 Composition/CH 4 Raw Syngas - Primary Reformer Outlet OptoDRS HH3 Composition/CO Raw Syngas - Secondary Reformer Outlet OptoDRS HH4 Composition/CO High Temperature Shift Converter Outlet OptoDRS HH5 Composition/ Low Temperature Shift Converter Outlet OptoDRS HH6 Composition/ Absorber Outlet - Feed to PSA OptoAST HH7 Composition/H 2 /N 2 PSA Unit H 2 Stream OptoAST HH8 CH 4 Leakage Recovery Stream OptoAST HH9 IGCC Plant SNG Production Analytics Overview Composition/CH 4 Raw Syngas from Gasifier Effluent OptoDRS SY1 Composition/H 2 /CO/ Syngas after Scrubber OptoDRS SY2 Composition/H 2 /CO/ Raw Syngas from Other Trains OptoDRS SY3 Composition/H 2 /CO/ Common Syngas Header after Scrubbers OptoDRS SY4 Composition/H 2 /CO/ Shift Converter Outlet OptoDRS SY5 Composition/H 2 /CO/ Absorber Outlet OptoDRS SY6 Composition/H 2 /CO/ SNG at Methanator Outlet OptoAST SY7 Composition/CH 4 /H 2 /CO/ SNG to Pipeline OptoAST SY8 Composition/CH 4 /H 2 / /N 2 Recovery Stream OptoAST SY9 Methanol Production Analytics Overview Carbon Number Natural Gas Feed to Primary Reformer OptoAST ME1 BTU Fuel Gas to Reformer Furnaces OptoAST ME2 Composition/CH 4 Raw Syngas - Primary Reformer Outlet OptoDRS ME3 Composition/H 2 /CO/ Raw Syngas - Secondary Reformer Outlet OptoDRS ME4 Composition/CH 4 Raw Syngas from Gasifier Effluent OptoDRS ME5 Composition/H 2 /CO/ Syngas after Scrubber OptoDRS ME6 Composition/H 2 /CO/ Make-up Syngas OptoAST ME7 Composition/H 2 /CO/ Syngas to Methanol Reactor OptoAST ME8 Composition Methanol Synthesis Loop Recycle OptoAST ME9 AM0 HY0 HH0 SY0 ME0

12 Head Office Queensland Western Australia New South Wales Victoria / Tasmania SA / NT Endress+Hauser Pty Ltd 16 Giffnock Ave, Macquarie Park NSW 2113 Phone Fax /35 Miles Platting Road Brisbane Technology Park, Eight Mile Plains QLD 4113 Phone Fax Unit C, 140 Abernethy Road, Belmont WA 6104 Phone Fax Level 1, 16 Giffnock Ave, Macquarie Park NSW 2113 Phone Fax Bldg 18, 270 Ferntree Gully Road, Notting Hill VIC 3168 Phone Fax Endress+Hauser Pty Ltd Phone Fax CP01117S/29/EN/01.15 info@au.endress.com